Active agent-containing articles

ABSTRACT

Active agent-containing articles, for example dryer-added articles and/or washing machine-added articles and/or hair care articles, and more particularly to consumable, single use, water-insoluble articles containing one or more active agents and optionally, one or more auxiliary ingredients, methods for making same, and methods for using same are provided.

FIELD OF THE INVENTION

The present invention relates to active agent-containing articles, forexample dryer-added articles and/or washing machine-added articlesand/or hair care articles, and more particularly to consumable, singleuse, water-insoluble articles containing one or more active agents andoptionally, one or more auxiliary ingredients, methods for making same,and methods for using same.

BACKGROUND OF THE INVENTION

Dryer-added articles in the past have consisted of a carrier sheet, suchas a thermoplastic nonwoven sheet, for example a polyester nonwovensheet that is coated and/or impregnated with a fabric conditioningactive agent and/or a holder that affixes to a dryer's drum and containsa refillable solid fabric conditioning active agent, often referred toas a dryer bar. During use, the fabric conditioning active agent is atleast partially transferred to (deposited on) fabrics from the sheetand/or dryer drum when being treated in a dryer. In the case of thecarrier sheet containing the fabric conditioning active agent, remnantsof the carrier sheet and/or other remains after use must be disposedabove. In the case of the dryer bar, which is a multi-use article, theholder remains affixed to the dryer drum and oftentimes at least aportion of the fabric conditioning active agent remains attached to theholder, since it is a multi-use article.

One problem with existing dryer-added articles is that at least aportion of the existing dryer-added articles and/or holder remains inthe dryer after use. In other words, at least a portion of the existingdryer-added articles and/or holder are not consumable after a single usein the dryer. The existing dryer added articles with their excess, notconsumed, material creates waste which must be disposed of.

Accordingly, there is a need for an active agent-containing article, forexample an active agent-containing dryer-added article that overcomesthe negatives described above by being a consumable, single use activeagent-containing article, for example a consumable, single use activeagent-containing dryer added article, a method for making same, and amethod for treating surfaces, such as fabrics with such an activeagent-containing article.

SUMMARY OF THE INVENTION

The present invention fulfills the needs described above by providing aconsumable, single use active agent-containing article, for example aconsumable, single use active agent-containing dryer added article, amethod for making same, and a method for using same.

One solution to the problem identified above is to provide a consumable,single use active agent-containing article, for example a consumable,single use active agent-containing dryer added article that is consumedduring use for treating fabrics in an automatic clothes dryer and/or ina washing machine wherein the water-insoluble article may form alamellar structure (exhibit a lamellar structure response) as measuredby the Lamellar Structure Test Method described herein and/or aconsumable, single use active agent-containing article for treatinghair.

In one example of the present invention, a consumable, single usearticle, for example a consumable, single use, water-insoluble article,such as a fibrous structure and/or film, comprising:

a. one or more active agents; and

b. optionally, one or more auxiliary ingredients;

wherein the article exhibits an Article Density of less than about 0.80g/cm³ as measured according to the Density Test Method; and

wherein the article exhibits a Free Melt Flow of greater than about 20%as measured according to the Free Melt Flow Test Method, is provided.

In another example of the present invention, a method for making aconsumable, single use article, for example a consumable, single use,water-insoluble article, such as a fibrous structure and/or film, themethod comprising the steps of:

a. providing a filament-forming composition comprising one or moreactive agents and optionally, one or more auxiliary ingredients; and

b. producing a consumable, single use article, for example a consumable,single use, water-insoluble article, such as a fibrous structure and/orfilm, from the filament-forming composition;

wherein the consumable, single use article exhibits an Article Densityof less than about 0.80 g/cm³ as measured according to the Density TestMethod; and

wherein the consumable, single use article exhibits a Free Melt Flow ofgreater than about 20% as measured according to the Free Melt Flow TestMethod, is provided.

In yet another example of the present invention, a package comprisingone or more consumable, single use articles according to the presentinvention, is provided.

In even yet another example of the present invention, a method fortreating surfaces, for example fabrics in need of treatment and/or hairin need of treatment, wherein the method comprises contacting one ormore fabrics and/or hair with one or more consumable, single usearticles according to the present invention such that the fabrics and/orhair are treated, is provided.

In one example, a method for depositing one or more active agents on afabric being treated in an automatic clothes dryer, the methodcomprising the steps of contacting the fabric with one or more activeagents from an article according to any of the preceding paragraphsduring operation of the dryer is provided.

In another example, a method for depositing one or more active agents ona fabric being treated in a washing machine, the method comprising thesteps of contacting the fabric with one or more active agents from anarticle according to any of the preceding paragraphs during operation ofthe washing machine is provided.

In another example, a method for depositing one or more active agents onhair being treated in a hair conditioning operation, the methodcomprising the steps of contacting the hair with one or more activeagents from an article according to any of the preceding paragraphsduring the hair conditioning operation is provided.

The present invention provides consumable, single use articles, methodsfor making same, packages containing same, and method for treatingsurfaces, for example fabric surfaces and/or hair surfaces, with suchconsumable, single use articles.

Accordingly, the present invention provides active agent-containingarticles, for example consumable, single use active agent-containingarticles useful for treating fabrics and/or hair, methods for makingsame, and methods for treating surfaces, such as fabrics and/or hairwith such articles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of an example of a fibrous element,in this case a filament, according to the present disclosure;

FIG. 2 is a schematic representation of an example of a fibrousstructure comprising a plurality of filaments according to the presentdisclosure;

FIG. 3 is another schematic representation of the article of FIG. 2,depicting article dimensions.

FIG. 4 is a scanning electron microscope photograph of a cross-sectionalview of an example of a fibrous structure according to the presentdisclosure;

FIG. 5 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentdisclosure;

FIG. 6 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentdisclosure;

FIG. 7 is a scanning electron microscope photograph of a cross-sectionalview of another example of a fibrous structure according to the presentdisclosure;

FIG. 8 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentdisclosure;

FIG. 9 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentdisclosure;

FIG. 10 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentdisclosure;

FIG. 11 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentdisclosure;

FIG. 12 is a schematic representation of an example of a film structureaccording to the present invention;

FIG. 13 is a schematic representation of another example of a filmstructure according to the present invention;

FIG. 14 is a schematic representation of an example of a process formaking an example of a fibrous structure according to the presentdisclosure;

FIG. 15 is a schematic representation of an example of a die with amagnified view used in the process of FIG. 14;

FIG. 16 is a schematic representation of an example of another processfor making an example of a fibrous structure according to the presentdisclosure;

FIG. 17 is a schematic representation of another example of a processfor making another example of a fibrous structure according to thepresent disclosure;

FIG. 18 is a schematic representation of another example of a processfor making another example of a fibrous structure according to thepresent disclosure; and

FIG. 19 is a representative image of an example of a patterned beltuseful in the processes for making the fibrous structure according tothe present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

“Article” as used herein refers to a consumer use unit, a consumer unitdose unit, a consumer use saleable unit, a single dose unit, or otheruse form comprising a unitary fibrous structure and/or film structureand/or comprising one or more fibrous structures and/or film structuresof the present invention.

“Fibrous structure” as used herein means a structure that comprises aplurality of fibrous elements and optionally, one or more particles. Inone example, a fibrous structure according to the present inventionmeans an association of fibrous elements and optionally, particles thattogether form a structure, such as a unitary structure, capable ofperforming a function. Particle may be blended with the fibrouselements, for example in a coform state via a coform process, may belayered between layers or plies of fibrous elements, and/or combinationsof these two within a fibrous structure of the present invention and/orarticle of the present invention.

“Film structure” as used herein means a structure comprising a singlecomponent (unlike a fibrous structure comprising a plurality ofcomponents; namely, a plurality of fibrous elements) in the form of acontinuous or substantially continuous sheet.

The fibrous structures and/or film structures of the present inventionmay be homogeneous or may be layered. If layered, the fibrous structuresand/or film structures may comprise at least two and/or at least threeand/or at least four and/or at least five layers, for example one ormore fibrous element layers, one or more particle layers and/or one ormore fibrous element/particle mixture layers and/or one or more filmlayers and/or one or more fibrous element layers and one or more filmlayers. A layer may comprise a particle layer within the fibrousstructure and/or films or between fibrous element and/or film layerswithin a fibrous structure and/or within a multi-layer film structure. Alayer comprising fibrous elements and/or a film layer may sometimes bereferred to as a ply. A ply may be a fibrous structure and/or a filmwhich may be homogeneous or layered as described herein.

In one example, a single-ply fibrous structure and/or film according tothe present invention or a multi-ply fibrous structure and/or multi-plyfilm comprising one or more fibrous structure plies and/or one or morefilm structure plies according to the present invention may exhibit abasis weight of less than 5000 g/m² as measured according to the BasisWeight Test Method described herein. In one example, the single- ormulti-ply fibrous structure and/or single- or multi-ply film structureaccording to the present invention may exhibit a basis weight of greaterthan 10 g/m² to about 5000 g/m² and/or greater than 10 g/m² to about3000 g/m² and/or greater than 10 g/m² to about 2000 g/m² and/or greaterthan 10 g/m² to about 1000 g/m² and/or greater than 20 g/m² to about 800g/m² and/or greater than 30 g/m² to about 600 g/m² and/or greater than50 g/m² to about 500 g/m² and/or greater than 300 g/m² to about 3000g/m² and/or greater than 500 g/m² to about 2000 g/m² as measuredaccording to the Basis Weight Test Method.

In one example, the fibrous structure of the present invention is a“unitary fibrous structure.”

“Unitary fibrous structure” as used herein is an arrangement comprisinga plurality of two or more and/or three or more fibrous elements thatare inter-entangled or otherwise associated with one another to form afibrous structure and/or fibrous structure plies. A unitary fibrousstructure of the present invention may be one or more plies within amulti-ply fibrous structure. In one example, a unitary fibrous structureof the present invention may comprise three or more different fibrouselements. In another example, a unitary fibrous structure of the presentinvention may comprise two or more different fibrous elements.

“Fibrous element” as used herein means an elongate particulate having alength greatly exceeding its average diameter, i.e. a length to averagediameter ratio of at least about 10. A fibrous element may be a filamentor a fiber. In one example, the fibrous element is a single fibrouselement rather than a yarn comprising a plurality of fibrous elements.

The fibrous elements of the present invention may be spun fromfilament-forming compositions also referred to as fibrouselement-forming compositions via suitable spinning process operations,such as meltblowing, spunbonding, electro-spinning, and/or rotaryspinning.

The fibrous elements of the present invention may be monocomponent(single, unitary solid piece rather than two different parts, like acore/sheath bicomponent) and/or multicomponent. For example, the fibrouselements may comprise bicomponent fibers and/or filaments. Thebicomponent fibers and/or filaments may be in any form, such asside-by-side, core and sheath, islands-in-the-sea and the like.

In one example as shown in FIG. 1, a fibrous element, for example afilament 10 of the present invention made from a fibrous element-formingcomposition of the present invention is such that one or more activeagents 12 may be present in the filament rather than on the filament,such as a coating composition comprising one or more active agents,which may be the same or different from the active agents in the fibrouselements and/or particles, if present. The total level of fibrouselement-forming materials and total level of active agents present inthe fibrous element-forming composition may be any suitable amount solong as the fibrous elements of the present invention are producedtherefrom.

“Filament” as used herein means an elongate particulate as describedabove that exhibits a length of greater than or equal to 5.08 cm (2 in.)and/or greater than or equal to 7.62 cm (3 in.) and/or greater than orequal to 10.16 cm (4 in.) and/or greater than or equal to 15.24 cm (6in.).

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments. Non-limiting examples of polymers that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose, such as rayon and/or lyocell, and cellulose derivatives,hemicellulose, hemicellulose derivatives, and synthetic polymersincluding, but not limited to polyvinyl alcohol and also thermoplasticpolymer filaments, such as polyesters, nylons, polyolefins such aspolypropylene filaments, polyethylene filaments, and biodegradablethermoplastic fibers such as polylactic acid filaments,polyhydroxyalkanoate filaments, polyesteramide filaments andpolycaprolactone filaments.

“Fiber” as used herein means an elongate particulate as described abovethat exhibits a length of less than 5.08 cm (2 in.) and/or less than3.81 cm (1.5 in.) and/or less than 2.54 cm (1 in.).

Fibers are typically considered discontinuous in nature. Non-limitingexamples of fibers include staple fibers produced by spinning a filamentor filament tow of the present invention and then cutting the filamentor filament tow into segments of less than 5.08 cm (2 in.) thusproducing fibers.

In one example, one or more fibers may be formed from a filament of thepresent invention, such as when the filaments are cut to shorter lengths(such as less than 5.08 cm in length). Thus, in one example, the presentinvention also includes a fiber made from a filament of the presentinvention, such as a fiber comprising one or more filament-formingmaterials and one or more active agents. Therefore, references tofilament and/or filaments of the present invention herein also includefibers made from such filament and/or filaments unless otherwise noted.Fibers are typically considered discontinuous in nature relative tofilaments, which are considered continuous in nature.

“Filament-forming composition” and/or “fibrous element-formingcomposition” and/or “film-forming composition” as used herein means anon-aqueous composition that is suitable for making a fibrous elementand/or film of the present invention such as by meltblowing orspunbonding (in the case of fibrous elements) and/or casting orextruding (in the case of films). The filament-forming compositioncomprises one or more active agents suitable for spinning into a fibrouselement and/or casting or extruding into a film. In addition to the oneor more active agents, the filament-forming composition may comprise oneor more auxiliary ingredients, such as one or more filament-formingmaterials, for example one or more structurants, that exhibit propertiesthat make them suitable for spinning into a fibrous element and/orcasting into a film. In one example, the auxiliary ingredients compriseone or more structurants, such as one or more polymers.

In one example, the filament-forming composition may be made by heatingand optionally stirring one or more active agents until the meltedactive agents are homogeneous. Then the homogeneous melted activeagents, which in this case is the filament-forming composition, can bespun into fibrous elements and/or cast or extruded into films.Alternatively, one or more auxiliary ingredients, such asfilament-forming materials, for example structurants, such as polymericstructurants and/or inorganic structurants, may be added, with orwithout stirring and/or agitation, to the homogeneous melted activeagents and dissolved, for example homogeneously dissolved, in and/ordispersed, for example homogeneously dispersed, throughout the meltedactive agents to form the filament-forming composition, which can thenbe spun into fibrous elements and/or cast or extruded into films.

In one example, a fibrous element, for example a filament of the presentinvention made from a fibrous element-forming composition of the presentinvention is such that one or more active agents may be present in thefilament rather than on the filament, such as a coating compositioncomprising one or more active agents, which may be the same or differentfrom the active agents in the fibrous elements and/or particles. Thetotal level of fibrous element-forming materials and total level ofactive agents present in the fibrous element-forming composition may beany suitable amount so long as the fibrous elements of the presentinvention are produced therefrom.

Similarly, in one example, a film structure of the present inventionmade from a film-forming composition of the present invention is suchthat one or more active agents may be present in the film rather than onthe film such as a coating composition comprising one or more activeagents, which may be the same or different from the active agents in thefilm structure. The total level of film-forming materials and totallevel of active agents present in the film-forming composition may beany suitable amount so long as the film structures of the presentinvention are produced therefrom.

In one example, one or more active agents, may be present in the fibrouselement and/or in the film structure and one or more additional activeagents may be present on a surface of the fibrous element and/or filmstructure as a coating. In another example, a fibrous element of thepresent invention may comprise one or more active agents that arepresent in the fibrous element when originally made, but then bloom to asurface of the fibrous element prior to and/or when exposed toconditions of intended use of the fibrous element.

“Filament-forming material” and/or “fibrous element-forming material” asused herein means a material, for example an auxiliary ingredient, suchas a structurant, for example a polymer that exhibits propertiessuitable for making a fibrous element and/or a film. Also, inorganicstructurants can act as fillers, viscosity modifiers, and/or to buildsolid structures, etc. In one example, the filament-forming material isa structurant. A “structurant” as used herein means a material, forexample a polymer, that improves the fibrous element spinning of themelted active agents, such as fatty alcohols, fatty quaternary ammoniumcompounds, fatty acids, etc. The structurant increases the shear andextensional viscosity of the melted active agents to enable fibrouselement formation. In one example, the structurant can be included at alevel of from about 1 wt % to about 50 wt % and/or from about 1 wt % toabout 30 wt % and/or from about 1 wt % to about 10 wt % and/or fromabout 2 wt % to about 6 wt % and/or from about 3 wt % to about 5 wt % ofthe filament-forming composition. In one example, the structurantexhibits a weight average molecular weight of from about 10,000 to about6,000,000 g/mol. The weight average molecular weight is computed bysumming the average molecular weights of each polymer raw materialmultiplied by their respective relative weight percentages by weight ofthe total weight of polymers present within the article. However, abalance is often struck between concentration and molecular weight, suchthat when a lower molecular weight species is used, it requires a higherlevel to result in optimal fibrous element spinning. Likewise, when ahigher molecular species is used, lower levels can be used to achieveoptimal fibrous element spinning. For example, a structurant having amolecular weight of from about 3,000,000 g/mol to about 5,000,000 g/molmay be included at a level of from about 3 wt % to about 6 wt % whereasa structurant having a molecular weight of from about 50,000 g/mol toabout 100,000 g/mol may be included at a level of from about 30 wt % toabout 50 wt %. In one example, the structurant is soluble in an oilymixture to enable viscosity build for fibrous element spinning. Inaddition, the structurant may also be soluble in water to promoteremoval and to prevent buildup. Suitable structurants include, but arenot limited to, polyvinylpyrrolidone, polydimethylacrylamides, andcombinations thereof. These polymers are oil (fatty alcohol, fatty acid,fatty quaternary ammonium compounds) soluble, water soluble, watermiscible, and capable of being produced at high molecular weights. Forexample, suitable polymers for use are PVP K120 from Ashland Inc.,having a molecular weight of about 3,500,000 g/mol, which is soluble inoil and water and enables fibrous elements to be formed and collectedonto a belt. Additional suitable polymers include copolymers ofpolyvinylpyrrolidone, such as Ganex® or PVP/VA (weight average molecularweight of about 50,000 g/mol) copolymers from Ashland Inc., which alsofunction as suitable structurants but require a higher level to beeffective due to their lower molecular weights. In addition, copolymersof polydimethylacrylamide also function as suitable structurants.Hydroxyl propyl cellulose can also function as a suitable structurant.

Non-limiting examples of structurants suitable for the present inventioninclude polymeric structurants, inorganic structurants, and mixturesthereof. In one example, the structurant comprises a polymericstructurant selected from the group consisting of: polylactams such aspolyvinylpyrrolidone and copolymers of vinylpyrrolidone,polydimethylacrylamide, copolymers of dimethylacrylamide, and mixturesthereof. In one example, the structurant comprises polyvinylpyrrolidone.In another example, the structurant comprises polydimethylacrylamide. Instill another example, the structure comprises polyvinylpyrrolidone andpolydimethylacrylamide. In one example, the structurant comprisesinorganic structurants selected from the group consisting of clays,silica, and mixtures thereof.

As used herein, “vinyl pyrrolidone copolymer” (and “copolymer” when usedin reference thereto) refers to a polymeric structurant of the followingstructure:

wherein n is an integer such that the polymeric structurant has thedegree of polymerization such that it possesses characteristicsdescribed herein. For purposes of clarity, the use of the term“copolymer” is intended to convey that the vinyl pyrrolidone monomer canbe copolymerized with other non-limiting monomers such as vinyl acetate,alkylated vinyl pyrrolidone, vinyl caprolactam, acrylic acid,methacrylate, acrylamide, methacrylamide, dimethacrylamide,alkylaminomethacrylate, and alkylaminomethacrylamide monomers.

“Particle” as used herein means a solid additive, such as a powder,granule, encapsulate, microcapsule, and/or prill. In one example, theparticle exhibits a median particle size of 2000 m or less as measuredaccording to the Median Particle Size Test Method described herein. Inanother example, the particle exhibits a median particle size of fromabout 1 μm to about 2000 μm and/or from about 1 μm to about 1600 μmand/or from about 1 μm to about 800 μm and/or from about 5 μm to about500 μm and/or from about 10 μm to about 300 μm and/or from about 10 μmto about 100 μm and/or from about 10 μm to about 50 μm and/or from about10 μm to about 30 μm as measured according to the Median Particle SizeTest Method described herein. The shape of the particle can be in theform of spheres, rods, plates, tubes, squares, rectangles, discs, stars,fibers or have regular or irregular random forms.

“Active agent-containing particle” as used herein means a solid additivecomprising one or more active agents. In one example, the activeagent-containing particle is an active agent in the form of a particle(in other words, the particle comprises 100% active agent(s)). Theactive agent-containing particle may exhibit a median particle size of2000 μm or less as measured according to the Median Particle Size TestMethod described herein. In another example, the active agent-containingparticle exhibits a median particle size of from about 1 μm to about2000 μm and/or from about 1 μm to about 800 μm and/or from about 5 μm toabout 500 μm and/or from about 10 μm to about 300 μm and/or from about10 μm to about 100 μm and/or from about 10 μm to about 50 μm and/or fromabout 10 μm to about 30 μm as measured according to the Median ParticleSize Test Method described herein. In one example, one or more of theactive agents is in the form of a particle that exhibits a medianparticle size of 20 μm or less as measured according to the MedianParticle Size Test Method described herein.

In one example of the present invention, the article, for examplefibrous structure and/or film structure, comprises a plurality ofparticles, for example active agent-containing particles, and aplurality of fibrous elements and/or film in a weight ratio ofparticles, for example active agent-containing particles to fibrouselements and/or film of 1:100 or greater and/or 1:50 or greater and/or1:10 or greater and/or 1:3 or greater and/or 1:2 or greater and/or 1:1or greater and/or 2:1 or greater and/or 3:1 or greater and/or 4:1 orgreater and/or 5:1 or greater and/or 7:1 or greater and/or 8:1 orgreater and/or 10:1 or greater and/or from about 10:1 to about 1:100and/or from about 8:1 to about 1:50 and/or from about 7:1 to about 1:10and/or from about 7:1 to about 1:3 and/or from about 6:1 to 1:2 and/orfrom about 5:1 to about 1:1 and/or from about 4:1 to about 1:1 and/orfrom about 3:1 to about 1.5:1.

In another example of the present invention, the article, for example afibrous structure, comprises a plurality of particles, for exampleactive agent-containing particles, and a plurality of fibrous elementsin a weight ratio of particles, for example active agent-containingparticles, to fibrous elements of from about 10:1 to about 1:1 and/orfrom about 8:1 to about 1.5:1 and/or from about 7:1 to about 2:1 and/orfrom about 6:1 to about 2.5:1.

In yet another example of the present invention, the article, forexample a fibrous structure, comprises a plurality of particles, forexample active agent-containing particles, and a plurality of fibrouselements in a weight ratio of particles, for example activeagent-containing particles, to fibrous elements of from about 1:1 toabout 1:100 and/or from about 1:15 to about 1:80, and/or from about 1:2to about 1:60 and/or from about 1:3 to about 1:50 and/or from about 1:3to about 1:40.

In another example, the article, for example a fibrous structure, of thepresent invention comprises a plurality of particles, for example activeagent-containing particles, at a basis weight of greater than 1 g/m²and/or greater than 10 g/m² and/or greater than 20 g/m² and/or greaterthan 30 g/m² and/or greater than 40 g/m² and/or from about 1 g/m² toabout 5000 g/m² and/or to about 3500 g/m² and/or to about 2000 g/m²and/or from about 1 g/m² to about 2000 g/m² and/or from about 10 g/m² toabout 1000 g/m² and/or from about 10 g/m² to about 500 g/m² and/or fromabout 20 g/m² to about 400 g/m² and/or from about 30 g/m² to about 300g/m² and/or from about 40 g/m² to about 200 g/m² as measured by theBasis Weight Test Method described herein.

In another example, the article, for example a fibrous structure and/orfilm structure, of the present invention comprises a plurality offibrous elements and/or film at a basis weight of greater than 1 g/m²and/or greater than 10 g/m² and/or greater than 20 g/m² and/or greaterthan 30 g/m² and/or greater than 40 g/m² and/or from about 1 g/m² toabout 3000 g/m² and/or from about 10 g/m² to about 5000 g/m² and/or toabout 3000 g/m² and/or to about 2000 g/m² and/or from about 20 g/m² toabout 2000 g/m² and/or from about 30 g/m² to about 1000 g/m² and/or fromabout 30 g/m² to about 500 g/m² and/or from about 30 g/m² to about 300g/m² and/or from about 40 g/m² to about 100 g/m² and/or from about 40g/m² to about 80 g/m² as measured by the Basis Weight Test Methoddescribed herein. In one example, the article, for example a fibrousstructure and/or film structure, comprises two or more layers whereinfibrous elements and/or film are present in at least one of the layersat a basis weight of from about 1 g/m² to about 500 g/m² as measuredaccording to the Basis Weight Test Method described herein.

“Additive” as used herein means any material present in the fibrouselement of the present invention that is not a filament-forming materialnor an active agent. In one example, an additive comprises a processingaid. In still another example, an additive comprises a filler.

In another example, an additive may comprise a plasticizer for thefibrous element. Non-limiting examples of suitable plasticizers for thepresent invention include polyols, copolyols, polycarboxylic acids,polyesters and dimethicone copolyols. Examples of useful polyolsinclude, but are not limited to, glycerin, diglycerin, propylene glycol,ethylene glycol, butylene glycol, pentylene glycol, cyclohexanedimethanol, hexanediol, 2,2,4-trimethylpentane-1,3-diol, polyethyleneglycol (200-600), pentaerythritol, sugar alcohols such as sorbitol,manitol, lactitol and other mono- and polyhydric low molecular weightalcohols (e.g., C2-C8 alcohols); mono di- and oligo-saccharides such asfructose, glucose, sucrose, maltose, lactose, high fructose corn syrupsolids, and dextrins, and ascorbic acid.

In one example, the plasticizer includes glycerin and/or propyleneglycol and/or glycerol derivatives such as propoxylated glycerol. Instill another example, the plasticizer is selected from the groupconsisting of glycerin, ethylene glycol, polyethylene glycol, propyleneglycol, glycidol, urea, sorbitol, xylitol, maltitol, sugars, ethylenebisformamide, amino acids, and mixtures thereof

In another example, an additive may comprise a rheology modifier, suchas a shear modifier and/or an extensional modifier. Non-limitingexamples of rheology modifiers include but not limited topolyacrylamide, polyurethanes and polyacrylates that may be used in thefibrous elements of the present invention. Non-limiting examples ofrheology modifiers are commercially available from The Dow ChemicalCompany (Midland, Mich.).

In yet another example, an additive may comprise one or more colorsand/or dyes that are incorporated into the fibrous elements of thepresent invention to provide a visual signal when the fibrous elementsare exposed to conditions of intended use and/or when an active agent isreleased from the fibrous elements and/or when the fibrous elements'morphology changes.

In even still yet another example, an additive may comprise one or moreanti-blocking and/or detackifying agents. Non-limiting examples ofsuitable anti-blocking and/or detackifying agents include starches,starch derivatives, crosslinked polyvinylpyrrolidone, crosslinkedcellulose, microcrystalline cellulose, silica, metallic oxides, calciumcarbonate, talc, mica, and mixtures thereof.

“Conditions of intended use” as used herein means the temperature,physical, chemical, and/or mechanical conditions that an article of thepresent invention is exposed to when the article is used for one or moreof its designed purposes. For example, if an article of the presentinvention is designed to be used in an automatic clothes dryer and/or ina washing machine for laundry care purposes, the conditions of intendeduse will include those temperature, chemical, physical and/or mechanicalconditions present in an automatic clothes dryer's clothes drying and/orconditioning operation and/or in a washing machine wherein thewater-insoluble article may form a lamellar structure (exhibit alamellar structure response) as measured by the Lamellar Structure TestMethod described herein. In another example, if an article of thepresent invention is designed to be used by a human as a shampoo and/orconditioner for hair care purposes, the conditions of intended use willinclude those temperature, chemical, physical and/or mechanicalconditions present during the shampooing and/or conditioning of thehuman's hair.

“Active agent” as used herein means a material that produces an intendedeffect in an environment external to an article of the presentinvention, such as when the article is exposed to conditions of intendeduse of the article. In one example, an active agent comprises a materialthat treats a surface, such as a soft surface (i.e., fabric, hair,skin).

“Treats” as used herein with respect to treating a surface means thatthe active agent provides a benefit to a surface or environment. Treatsincludes regulating and/or immediately improving a surface's orenvironment's appearance, cleanliness, smell, purity and/or feel. In oneexample treating in reference to treating a keratinous tissue (forexample skin and/or hair) surface means regulating and/or immediatelyimproving the keratinous tissue's cosmetic appearance and/or feel. Forinstance, “regulating skin, hair, or nail (keratinous tissue) condition”includes: thickening of skin, hair, or nails (e.g, building theepidermis and/or dermis and/or sub-dermal [e.g., subcutaneous fat ormuscle] layers of the skin, and where applicable the keratinous layersof the nail and hair shaft) to reduce skin, hair, or nail atrophy,increasing the convolution of the dermal-epidermal border (also known asthe rete ridges), preventing loss of skin or hair elasticity (loss,damage and/or inactivation of functional skin elastin) such aselastosis, sagging, loss of skin or hair recoil from deformation;melanin or non-melanin change in coloration to the skin, hair, or nailssuch as under eye circles, blotching (e.g., uneven red coloration dueto, e.g., rosacea) (hereinafter referred to as “red blotchiness”),sallowness (pale color), discoloration caused by telangiectasia orspider vessels, and graying hair. Treats may include providing a benefitto fabrics like during a cleaning or softening in a laundry machine,providing a benefit to hair like during shampooing, conditioning, orcoloring of hair, or providing a benefit to environments like a toiletbowl by cleaning or disinfecting it.

In another example, treating means removing stains and/or odors fromfabric articles, such as clothes, towels, and linens.

“Fabric care active agent” as used herein means an active agent thatwhen applied to a fabric provides a benefit and/or improvement to thefabric. Non-limiting examples of benefits and/or improvements to afabric include conditioning, including softening, cleaning (for exampleby surfactants), stain removal, stain reduction, wrinkle removal, colorrestoration, static control, wrinkle resistance, permanent press, wearreduction, wear resistance, pill removal, pill resistance, soil removal,soil resistance (including soil release), shape retention, shrinkagereduction, softness, fragrance, anti-bacterial, anti-viral, odorresistance, and odor removal.

“Keratinous tissue active agent” as used herein means an active agentthat may be useful for treating keratinous tissue (e.g., hair, skin, ornails) condition. For a hair care active agent, “treating” or“treatment” or “treat” includes regulating and/or immediately improvingkeratinous tissue cosmetic appearance and/or feel. For instance,“regulating skin, hair, or nail condition” includes: thickening of skin,hair, or nails (e.g., building the epidermis and/or dermis and/orsub-dermal [e.g., subcutaneous fat or muscle] layers of the skin, andwhere applicable the keratinous layers of the nail and hair shaft) toreduce skin, hair, or nail atrophy, increasing the convolution of thedermal-epidermal border (also known as the rete ridges), preventing lossof skin or hair elasticity (loss, damage and/or inactivation offunctional skin elastin) such as elastosis, sagging, loss of skin orhair recoil from deformation; melanin or non-melanin change incoloration to the skin, hair, or nails such as under eye circles,blotching (e.g., uneven red coloration due to, e.g., rosacea)(hereinafter referred to as “red blotchiness”), sallowness (pale color),discoloration caused by telangiectasia or spider vessels, and grayinghair. Another example of keratinous tissue active agent may be an activeagent used in the shampooing, conditioning, or dyeing of hair.

“Weight ratio” as used herein means the ratio between two materials ontheir dry basis. For example, the weight ratio of filament-formingmaterials to active agents within a fibrous element is the ratio of theweight of filament-forming material on a dry weight basis (g or %) inthe fibrous element to the weight of additive, such as active agent(s)on a dry weight basis (g or %—same units as the filament-formingmaterial weight) in the fibrous element. In another example, the weightratio of particles to fibrous elements within a fibrous structure is theratio of the weight of particles on a dry weight basis (g or %) in thefibrous structure to the weight of fibrous elements on a dry weightbasis (g or %—same units as the particle weight) in the fibrousstructure.

“Water-insoluble” with respect to an article and/or material as usedherein means an article and/or material of the present invention thatdoes not dissolve in excess water and/or is not miscible in water. Inother words, a water-insoluble article when subjected to agitation inexcess water may break apart into pieces of the article, but the piecesremain intact in the water. In another example, the article is stillwater-insoluble even if the article or pieces of the article swell inthe excess water so long as the article and/or pieces of the articleremain intact. In one example, an article and/or fibrous elements and/orfilms and/or materials that exhibit a lamellar structure (exhibit alamellar structure response) as determined according to the LamellarStructure Test Method are considered water-insoluble herein.

In one example, the article is water-insoluble. As defined herein,water-insoluble means that the article does not completely dissolve ordisintegrate when in contact with moisture from the laundered fabrics inthe automatic drying process or when in contact with the aqueouswash/rinse bath of the washing process. Where the articles are designedfor use in the dryer, water-insoluble auxiliary ingredients, whenpresent, are used instead of water-soluble auxiliary ingredients becausewater-soluble auxiliary ingredients, which dissolve and/or disintegratein the presence of water, have the potential to stain or otherwisedamage any fabrics being dried in the presence of the articles when theycontact a fabric.

“Ambient conditions” as used herein means 23° C.±1.0° C. and a relativehumidity of 50%±2%.

“Weight average molecular weight” as used herein means the weightaverage molecular weight as determined using the industry standardmethod, gel permeation chromatography.

“Article dimensions,” as used herein, refers to the length, width,height, mass, volume, density, and the like, of an article.

“Length,” as used herein with respect to a fibrous element, means thelength along the longest axis of the fibrous element from one terminusto the other terminus. If a fibrous element has a kink, curl or curvesin it, then the length is the length along the entire path of thefibrous element from one terminus to the other terminus. With respect todimensions of an article, “length” may be defined differently. Forexample, with respect to articles of irregular shape, the length refersto the maximum feret or caliper diameter, which is the longest distancebetween two parallel planes tangential to the boundary of the article.For a rectilinear-shaped article, for example, the length refers to thedistance from one edge to an opposite edge. In one example, an averagelength can be provided by measuring ten substantially similar replicatearticles, compiling an average of the ten individual article lengthmeasurements, and reporting the value to the nearest 0.01 cm, where theindividual article length measurements can be taken by any appropriateinstrument that is calibrated, NIST traceable, and capable of ameasurement to the nearest 0.01 cm. The length of an article, forexample, can be measured according to the Width and Length Test Methoddescribed herein.

“Diameter” as used herein, with respect to a fibrous element, ismeasured according to the Diameter Test Method described herein. In oneexample, a fibrous element of the present invention exhibits a diameterof less than 100 μm and/or less than 75 μm and/or less than 50 μm and/orless than 25 μm and/or less than 20 μm and/or less than 15 μm and/orless than 10 μm and/or less than 6 μm and/or greater than 1 μm and/orgreater than 3 μm as measured according to the Diameter Test Methoddescribed herein.

“Width,” as used herein with respect to dimensions of an article, mayrefer to the measurement according to its conventional definition. For arectilinear-shaped article, for example, the width refers to thedistance from one edge to an opposite edge. However, with respect toarticles of irregular shape, the width refers to the maximum feret orcaliper diameter, which is the longest distance between two parallelplanes tangential to the boundary of the article. In one example, anaverage width can be provided by measuring ten substantially similarreplicate articles, compiling an average of the ten individual articlewidth measurements, and reporting the value to the nearest 0.01 cm,where the individual article width measurements can be taken by anyappropriate instrument that is calibrated, NIST traceable, and capableof a measurement to the nearest 0.01 cm. The width of an article, forexample, can be measured according to the Width and Length Test Methoddescribed herein.

“Height,” as used herein with respect to dimensions of an article, mayrefer to the measurement according to its conventional definition. Theheight (thickness), of an article, for example, can be measuredaccording to the Height Test Method described herein.

“Volume,” as used herein with respect to dimensions of an article, mayrefer to the measurement according to its conventional definition. Forexample, the volume of an article can be calculated by measuring aprojected area of the article, as viewed orthogonally to a plane of thelength and width of the article, and multiplying the area by the heightof the article. In one example, an average volume can be provided bymeasuring ten substantially similar replicate articles, compiling anaverage of the ten individual article volume measurements, and reportingthe value to the nearest 0.01 cm³. The volume of an article, forexample, can be measured according to the Volume Test Method describedherein.

“Mass,” as used herein with respect to an article, may refer to themeasurement according to its conventional definition. For example, themass of an article can be measured using a top loading analyticalbalance with a resolution of +0.01 g, where the balance is protectedfrom air drafts and other disturbances by a draft shield. Afterconditioning the article, the mass of the article can be measured to thenearest 0.01 g. In one example, an average mass can be provided bymeasuring ten substantially similar replicate articles, compiling anaverage of the ten individual article mass measurements, and reportingthe value to the nearest 0.01 g. The mass of an article, for example,can be measured according to the Mass Test Method described herein.

“Article Density,” as used herein with respect to an article, may referto the measurement according to its conventional definition, such thatthe article density may be calculated by dividing the mass of thearticle by its volume. In one example, the article density can bereported to the nearest 0.01 g/cm³. The density of an article, forexample, can be measured according to the Density Test Method describedherein.

“Triggering condition” as used herein in one example means anything, asan act or event, that serves as a stimulus and initiates or precipitatesa change in the article or portion of the article of the presentinvention, such as a loss or altering of the article's physicalstructure and/or a release of an active agent therefrom. In anotherexample, the triggering condition may be present in an environment, suchas heat within an automatic clothes dryer, when an article of thepresent invention is added to the automatic clothes dryer and/or whenadded to a wash liquor, such as water and optionally detergent, withfabrics, for example in a washing machine wherein the water-insolublearticle may form a lamellar structure (exhibit a lamellar structureresponse) as measured by the Lamellar Structure Test Method describedherein.

Article

The articles of the present invention may comprise a plurality offibrous elements, for example a plurality of filaments, such as aplurality of active agent-containing filaments, and/or one or morefilms, for example one or more active agent-containing films, andoptionally, one or more particles, for example one or more activeagent-containing particles, such as water-soluble, activeagent-containing particles and/or water-insoluble particles, such aszeolites, porous zeolites, perfume-loaded zeolites, active-loadedzeolites, silicas, perfume-loaded silicas, active-loaded zeolites,perfume microcapsules, clays, and mixtures thereof. In certain examples,the article can be substantially formed from non-filament containingstructures.

Without wishing to be bound by theory, it is believed that articledimensions can contribute to achieving the most consumer-preferredcombination of performance factors of the article, with such factorsincluding consumer-preferred article flexibility, release of activeagents such as transfer to clothes in a dryer, compact storage ofproduct, and/or dispensing and does so without leaving behind a carriersheet or unwanted residue on the treated surfaces, such as fabricsand/or hair. The article and/or product comprising the article may be inthe form of a roll (roll form or rolled product), for example multiplearticles connected to adjacent sheets by perforation lines fordispensing individual articles from the rolled form wherein the articleis convolutely wound upon itself about a core or without a core to forma rolled article. In one example, a multi-article sheet productcomprising a plurality of articles separated from adjacent articles byperforation lines is provided. Alternatively, the article may be in theform of discrete, individual sheets or in a non-rolled form of multiplearticles connected to adjacent sheets by perforation lines fordispensing individual articles from the non-rolled form. In yet anotherexample, the article of the present invention is a standalone entityready for use and a collection and/or number of these entities may bedistributed to consumers in a product-shipping assembly, for example aprotective product-shipping assembly.

Furthermore, it is believed that article dimensions can contribute toachieving a product-shipping assembly that can provide desirablepackaging properties, such as minimized packaging sizes, reducedshipping costs, and a maximized ratio of an article volume to apackaging volume, while still providing sufficient protection for thearticles. For example, it is believed that providing desirable articledimensions can facilitate reduction of dunnage, thereby reducing costsand waste; improve efficiency in shipping by, for example, providing ashipping container that can fit in a mail slot; and ensure sufficientimmobilization and protection of the articles by, for example,minimizing the space in which the article can move within the shippingcontainer.

In certain examples, the article can have a length of from about 1 cm toabout 23 cm; from about 2 cm to about 20 cm; from about 2 cm to about 18cm; from about 3 cm to about 15 cm; from about 3 cm to about 12 cm; fromabout 4 cm to about 8 cm; from about 4 cm to about 6 cm; or from about 5cm to about 6 cm. In certain examples, the article can have a length offrom about 1 cm to about 10 cm; from about 2 cm to about 10 cm; or fromabout 7 cm to about 9 cm as measured according to the Width and LengthTest Method described herein.

In certain examples, the article can have a width of from about 1 cm toabout 15 cm; from about 2 cm to about 11 cm; from about 2 cm to about 10cm; from about 3 cm to about 9 cm; from about 4 cm to about 8 cm; orfrom about 4 cm to about 6 cm as measured according to the Width andLength Test Method described herein. In certain examples, the articlecan have a width of from about 1 cm to about 6 cm; from about 2 cm toabout 6 cm; from about 3 cm to about 5 cm; or from about 3.5 cm to about4.5 cm as measured according to the Width and Length Test Methoddescribed herein. In other examples, the article can have a width offrom about 6 cm to about 8 cm as measured according to the Width andLength Test Method described herein.

In certain examples, a ratio of a length of an article to its width canbe from about 3:1 to about 0.5:1; from about 5:2 to about 0.5:1; or fromabout 2:1 to about 1:1 as measured according to the Width and LengthTest Method described herein.

The article can have a height, or thickness, of about 0.01 mm orgreater; about 0.05 mm or greater; about 0.1 mm or greater; about 0.5 orgreater; about 1 mm or greater; about 2 mm or greater; about 3 mm orgreater; or about 4 mm or greater as measured according to the HeightTest Method described herein. In certain examples, the article can havea height, or thickness, of about 50 mm or less; about 20 mm or less;about 10 mm or less; about 8 mm or less; about 6 mm or less; about 5 mmor less; about 4 mm or less; about 3 mm or less; about 2 mm or less;about 1 mm or less; about 0.5 mm or less; or about 0.3 mm as measuredaccording to the Height Test Method described herein. Thus, in certainexamples, the article can have a height from about 0.01 mm to about 50mm; from about 0.01 to about 44 mm; from about 0.1 mm to about 50 mm;from about 0.1 to about 44 mm; from about 1 mm to about 20 mm; or fromabout 1 mm to about 5 mm as measured according to the Height Test Methoddescribed herein. In certain examples, the article can have a height, orthickness, of from about 3 mm to about 12 mm; or from about 4 mm toabout 10 mm as measured according to the Height Test Method describedherein.

The article can have a volume of from about 0.25 cm³ to about 60.00 cm³;from about 0.50 cm³ to about 60.00 cm³; from about 0.50 cm³ to about50.00 cm³; from about 1.00 cm³ to about 40.00 cm³; from about 1.00 cm³to about 30.00 cm³; from about 2.00 cm³ to about 20.00 cm³; from about3.00 cm³ to about 20.00 cm³; from about 4.00 cm³ to about 15.00 cm³; orfrom about 4.00 cm³ to about 10.00 cm³ as measured according to theVolume Test Method described herein. In certain examples, the articlecan have a volume of from about 3.00 cm³ to about 6.00 cm³ as measuredaccording to the Volume Test Method described herein. In other examples,the article can have a volume of from about 20.00 cm³ to about 35.00cm³; or from about 24.00 cm³ to about 30.00 cm³ as measured according tothe Volume Test Method described herein.

The article can have a mass of about 10 g or less; about 8 g or less;about 6 g or less; about 5 g or less; about 3 g or less; about 2 g orless; about 1 g or less; and/or about 0.10 g or greater and/or about0.15 g or greater and/or about 0.20 g or greater and/or about 0.40 g orgreater and/or 0.50 g or greater as measured according to the Mass TestMethod described herein. In certain examples, the article can have amass of from about 0.10 g to about 10 g; from about 0.10 g to about 8 g;from about 0.1 g to about 6 g; from about 0.15 g to about 5 g; fromabout 0.20 g to about 3 g; from about 0.20 g to about 2 g; from about0.20 g to about 1 g as measured according to the Mass Test Methoddescribed herein.

The article can have an article density of about 0.05 g/cm³ or greater;about 0.08 g/cm³ or greater; about 0.10 g/cm³ or greater; about 0.15g/cm³ or greater; about 0.20 g/cm³ or greater; about 0.25 g/cm³ orgreater; about 0.30 g/cm³ or greater; about 0.35 g/cm³ or greater; orabout 0.40 g/cm³ or greater and/or less than about 0.80 g/cm³ and/orless than about 0.75 g/cm³ and/or less than about 0.70 g/cm³ and/or lessthan about 0.60 g/cm³ and/or less than 0.50 g/cm³ as measured accordingto the Density Test Method described herein. In certain examples, thearticle can have an article density of about 0.80 g/cm³ or less; about0.60 g/cm³ or less; about 0.50 g/cm³ or less; about 0.40 g/cm³ or less;about 0.35 g/cm³ or less; about 0.30 g/cm³ or less; about 0.25 g/cm³ orless; about 0.20 g/cm³ or less; about 0.15 g/cm³ or less; about 0.12g/cm³ or less; about 0.10 g/cm³ or less; and/or greater than about 0.08g/cm³ and/or greater than about 0.05 g/cm³ as measured according to theDensity Test Method described herein. Thus, in certain examples, thearticle can have an article density of from about 0.05 g/cm³ to about0.80 g/cm³; from about 0.08 g/cm³ to about 0.80 g/cm³; from about 0.1g/cm³ to about 0.80 g/cm³; from about 0.20 g/cm³ to about 0.60 g/cm³; orfrom about 0.20 g/cm³ to about 0.40 g/cm³ as measured according to theDensity Test Method described herein. In certain examples, the articlecan have an article density of from greater than about 0.05 g/cm³ toless than about 0.80 g/cm³ and/or from greater than about 0.05 g/cm³ toless than about 0.60 g/cm³ and/or from greater than about 0.05 g/cm³ toless than about 0.30 g/cm³ and/or from greater than about 0.10 g/cm³ toless than about 0.20 g/cm³ as measured according to the Density TestMethod described herein.

In certain examples, the article has one or more of the followingdimensions: a width from about 1 cm to about 15 cm (as measuredaccording to the Width and Length Test Method described herein); alength from about 1 cm to about 23 cm (as measured according to theWidth and Length Test Method described herein); a height from about 0.01mm to about 50 mm (as measured according to the Height Test Methoddescribed herein); a mass from about 0.10 g to about 10 g (as measuredaccording to the Mass Test Method described herein); a volume from about0.25 cm³ to about 60.00 cm³ (as measured according to the Volume TestMethod described herein); and an article density from about 0.05 g/cm³to about 0.80 g/cm³ (as measured according to the Article Density TestMethod described herein). In certain examples, the article has one ormore of a width from about 1 cm to about 15 cm (as measured according tothe Width and Length Test Method described herein); a length from about1 cm to about 23 cm (as measured according to the Width and Length TestMethod described herein); and a height from about 0.01 mm to about 50 mm(as measured according to the Height Test Method described herein). Incertain examples, the article has one or more of a mass from about 0.10g to about 10 g (as measured according to the Mass Test Method describedherein); a volume from about 0.25 cm³ to about 60.00 cm³ (as measuredaccording to the Volume Test Method described herein); and an articledensity from about 0.05 g/cm³ to about 0.80 g/cm³ (as measured accordingto the Density Test Method described herein). In certain examples, thearticle has one or more of a width from about 1 cm to about 15 cm (asmeasured according to the Width and Length Test Method describedherein); a length from about 1 cm to about 23 cm (as measured accordingto the Width and Length Test Method described herein); and a height fromabout 0.01 mm to about 50 mm (as measured according to the Height TestMethod described herein); and one or more of a mass from about 0.10 g toabout 10 g (as measured according to the Mass Test Method describedherein); a volume from about 0.25 cm³ to about 60.00 cm³ (as measuredaccording to the Volume Test Method described herein); and an articledensity from about 0.05 g/cm³ to about 0.80 g/cm³ (as measured accordingto the Density Test Method described herein).

A product-shipping assembly can include a plurality of articles. Incertain examples, each article can include one or more fibrous elements,wherein at least one of the fibrous elements includes one or morefilament-forming materials, and one or more active agents releasablefrom the one or more fibrous elements. In some examples, an article maybe substantially formed from non-filament containing structures. Each ofthe plurality of articles can have dimensions in accordance to thosedescribed herein. The product-shipping assembly can further include ashipping container defining an internal volume sized to removablycontain the product.

In certain examples, the product-shipping assembly can further include asupport member.

In certain examples, the support member can be in contact with theproduct, and in some examples, the support member can be attached to theproduct. The support member can support one or more of the plurality ofarticles and/or facilitate the securement thereof within the shippingcontainer. In one example, the support member can be a tray, where thetray can be sized to fit within the shipping container, such that theplurality of articles may be slidably removed from the shippingcontainer while being substantially contained within the tray. It willbe appreciated, however, that a support member may be provided in any ofa variety of suitable configurations. The product-shipping assembly mayfurther include one or more dividers, wherein the one or more dividersseparate the plurality of articles. In certain examples, the one or moredividers can provide boundaries between multiple compartments within theshipping container, where the plurality of articles can be dividedbetween the multiple compartments, separated by the one or moredividers.

In certain examples, the product-shipping assembly may include a barrierto humidity, liquids (e.g., water), and scent escape. In certainexamples, the shipping container can include a protective coatingapplied to an interior of the shipping container, where the protectivecoating can serve as the barrier. In one example, the protective coatingcan be a thin polymeric film. However, it will be appreciated that aprotective coating can be any of a variety of suitable coatings known inthe art, and the protective coating may be applied through anyconventional coating methods known in the art. In certain examples, theprotective coating can define the internal volume of the shippingcontainer or be included within the internal volume of the shippingcontainer. The protective coating can be water impermeable, water vaporresistant, and/or scent impermeable.

In other examples, the product-shipping assembly can include one or moreoverwraps, where the one or more overwraps can serve as the barrier. Incertain examples, the one or more overwraps can fully or at leastpartially wrap an exterior of the shipping container. In certainexamples, the one or more overwraps can fully or at least partiallycover or surround one or more articles of the plurality of articles. Incertain examples, the one or more overwraps can further serve tofacilitate the securement of the plurality of articles within theshipping container. In one example, the one or more overwraps cansubstantially wrap each article, and the overwrap may seal the articletherein. The one or more overwraps may be a shrink wrap, a film wrap, apaper wrap, and/or any of a variety of other suitable wraps. Like theprotective coating, in certain examples, the one or more overwraps canbe water impermeable, water vapor resistant, and/or scent impermeable.

In certain examples, the product-shipping assembly can further include avent. The vent can allow for off-gassing of, for example, one or morescents, carbon dioxide, oxygen, water vapor, or other gases from theproduct-shipping assembly. In one example, the vent may include one ormore apertures in, for example, a shipping container and/or one or moreoverwraps.

In certain examples, however, the product-shipping assembly may besubstantially dunnage-free, such that the product-shipping assembly mayinclude minimal excessive protective packaging materials, such as bubblewrap, Styrofoam, and the like, or be completely free thereof. In oneexample, a ratio of a volume of the plurality of articles to theinternal volume can be about 0.8 or greater. In certain examples, theratio of the volume of the plurality of articles to the internal volumecan be about 0.85 or greater; about 0.9 or greater; or about 0.95 orgreater.

The shipping container can be any package, box, carton, bag, wrap, orother conventional type of receptacle used in the packing anddistribution of products, as described above. In particular, theshipping container can be suitable for use in e-commerce. In oneexample, the shipping container can have a width of about 6 inches orless; a length of about 10 inches or less; and a height of about 1.75inches or less. In such an example, the shipping container may be sizedand shaped to fit into a conventional mail slot. It will be appreciated,however, that a shipping container can be provided in any of a varietyof suitable sizes, shapes, and configurations.

The plurality of articles may include from about 2 articles to about 144articles, and any amount of articles in between. For example, theplurality of articles can include about 2 articles or more; about 8articles or more; about 12 articles or more; about 18 articles or more;about 24 articles or more; about 25 articles or more; about 30 articlesor more; about 36 articles or more; about 40 articles or more; about 48articles or more; about 50 articles or more; about 60 articles or more;or about 64 articles or more. In certain examples, at least two articlesof the plurality of articles can have different scents.

The product-shipping assembly can further include a water scavengingmaterial. In one example, the water scavenging material can be adesiccant. However, it will be appreciated that the water scavengingmaterial can be any of a variety of suitable water scavenging materialsknown in the art.

In one example, the fibrous elements and/or particles may be arrangedwithin the fibrous structure and thus an article comprising the fibrousstructure to provide the article with two or more regions or layers thatcomprise different active agents. For example, one region of the articlemay comprise anti-static agents and another region of the article maycomprise fabric conditioning active agents.

With respect to an article including one or more fibrous elements, thefibrous elements and/or fibrous structures of the present invention arein solid form. However, the filament-forming composition used to makethe fibrous elements of the present invention may be in the form of aliquid.

In one example, the fibrous structure comprises a plurality of identicalor substantially identical from a compositional perspective of fibrouselements according to the present invention.

In another example, the fibrous structure may comprise two or moredifferent fibrous elements according to the present invention.Non-limiting examples of differences in the fibrous elements may bephysical differences such as differences in diameter, length, texture,shape, rigidness, elasticity, and the like; chemical differences such ascrosslinking level, solubility, melting point, Tg, active agent,filament-forming material, color, level of active agent, basis weight,level of filament-forming material, presence of any coating on fibrouselement, biodegradable or not, hydrophobic or not, contact angle, andthe like; differences in whether the fibrous element loses its physicalstructure when the fibrous element is exposed to conditions of intendeduse; differences in whether the fibrous element's morphology changeswhen the fibrous element is exposed to conditions of intended use; anddifferences in rate at which the fibrous element releases one or more ofits active agents when the fibrous element is exposed to conditions ofintended use. In one example, two or more fibrous elements and/orparticles within the fibrous structure may comprise different activeagents. This may be the case where the different active agents may beincompatible with one another, for example an anionic surfactant (suchas a shampoo active agent) and a cationic surfactant (such as a hairconditioner active agent).

In another example, the fibrous structure may exhibit different regions,such as different regions of basis weight, density and/or caliper. Inyet another example, the fibrous structure may comprise texture on oneor more of its surfaces. A surface of the fibrous structure may comprisea pattern, such as a non-random, repeating pattern. The fibrousstructure may be embossed with an emboss pattern. In another example,the fibrous structure may comprise apertures. The apertures may bearranged in a non-random, repeating pattern.

In one example, the fibrous structure may comprise discrete regions offibrous elements that differ from other parts of the fibrous structure.

The fibrous structure of the present invention may be used as is or maybe coated with one or more active agents.

In one example, a fibrous structure can exhibit a thickness of greaterthan 0.01 mm and/or greater than 0.05 mm and/or greater than 0.1 mmand/or to about 50 mm and/or to about 20 mm and/or to about 10 mm and/orto about 5 mm and/or to about 2 mm and/or to about 0.5 mm and/or toabout 0.3 mm as measured by the Thickness Test Method described herein.

Non-limiting examples of other fibrous structures suitable for thepresent invention are disclosed in U.S. Published Patent Application No.2013/0171421 A1 and U.S. Pat. No. 9,139,802 are hereby incorporated byreference herein.

The articles of the present invention may exhibit one or more of thefollowing properties.

In one example, the articles and/or fibrous elements and/or films of thepresent invention may exhibit a lamellar structure (exhibit a lamellarstructure response) upon wetting as determined by the Lamellar StructureTest Method described herein.

In one example, the articles and/or fibrous elements and/or films of thepresent invention may exhibit a lamellar structure (exhibit a lamellarstructure response) upon wetting as determined by the Lamellar StructureTest Method described herein, but does not exhibit a lamellar structure(exhibit a lamellar structure response) in a conditioned only, dry stateas determined by the Lamellar Structure Test Method.

In one example, the articles of the present invention may exhibit an AirPermeability of at least 20 and/or at least 40 and/or at least 60 and/orat least 80 and/or less than 7000 and/or less than 6000 and/or less than5000 and/or less than 4000 and/or less than 3000 and/or less than 2000L/m²/s as measured according to the Air Permeability Test Methoddescribed herein.

In one example, the articles of the present invention may exhibit a FreeMelt Flow of greater than about 20% and/or greater than about 30% and/orgreater than about 40% and/or greater than about 50% and/or greater thanabout 60% and/or greater than about 70% and/or greater than about 80%and/or greater than about 85% and/or greater than about 90% and/orgreater than about 95% and/or greater than about 97% and/or greater thanabout 98% and/or greater than about 99% and/or about 100% as measuredaccording to the Free Melt Flow Test Method described herein. In oneexample, the articles of the present invention may exhibit a Free MeltFlow of from about 20% to about 100% and/or from about 30% to about 100%and/or from about 40% to about 100% and/or from about 50% to about 100%and/or from about 60% to about 99% and/or from about 70% to about 99%and/or from about 80% to about 99% and/or from about 90% to about 99% asmeasured according to the Free Melt Flow Test Method described herein.

In one example, the article is a non-woven comprising a fibrousstructure comprising one or more fibrous elements, for example aplurality of filaments. The article may comprise two or more nonwovens,a multi-ply nonwoven and/or multi-ply fibrous structure and/or multi-plyfilm.

In one example, the article, for example fibrous structure and/or film,may comprise one or more apertures.

In one example, the article exhibits a geometric mean peak elongation ofabout 5% or greater as measured according to the Tensile Test Method.

In one example, the article exhibits a geometric mean modulus of about5000 g/cm or less as measured according to the Tensile Test Method.

In one example, the article exhibits a geometric mean tensile strengthof about 100 g/in or more according to the Tensile Test Method.

In one example, the article exhibits a water content of from about 0% toabout 20% and/or from about 0% to about 5% as measured according to theWater Content Test Method. In one example, the article exhibits a watercontent of from about 2% to about 15% and/or from about 2% to about 10%and/or from about 5% to about 10% as measured according to the WaterContent Test Method.

In one example, the article comprises adhesive or a material thatfunctions as an adhesive, for example on one or more surfaces of thearticle to attach the article to an automatic clothes dryer internaldrum surface.

In one example, during use of the article in an automatic clothes dryeroperation, the article transfers (deposits) at least a portion, and/orsubstantially all of its mass to fabrics being treated, for exampledried and/or conditioned, in the automatic clothes dryer.

In one example, during use of the article in a washing machineoperation, the article transfers (deposits) at least a portion, and/orsubstantially all of its mass to fabrics being treated, for examplewashed and/or conditioned, in the washing machine.

In one example, the fibrous elements and/or particles may be arrangedwithin the fibrous structure to provide the fibrous structure with twoor more regions or layers that comprise different active agents. Forexample, one region of the fibrous structure may comprise bleachingagents and/or surfactants and another region of the fibrous structuremay comprise softening agents.

As shown in FIG. 2, an example of an article 20 of the presentinvention, for example a multi-ply fibrous structure according to thepresent invention may comprise two or more different fibrous structurelayers or plies 22, 24 (in the z-direction of the article 20 of fibrouselements, in this case filaments, 10 of the present invention that formthe fibrous structures of the article 20. The filaments 10 in layer 22may be the same as or different from the filaments 10 in layer 24. Eachlayer or ply 22, 24 may comprise a plurality of identical orsubstantially identical or different filaments. For example, filamentsthat may release their active agents at a faster rate than others withinthe article 20 and/or one or more fibrous structure layers or plies 22,24 of the article 20 may be positioned as an external surface of thearticle 20. The layers or plies 22 and 24 may be associated with eachother by mechanical entanglement at their interface between the twolayers or plies and/or by thermal or adhesive bonding and/or bydepositing one of the layers or plies onto the other existing layer orply, for example spinning the fibrous elements of layer or ply 22 ontothe surface of the layer or ply 24. FIG. 3 shows another view of thearticle 20, with plies 22 and 24. With respect to the article dimensionsdescribed above, the length (L), width (W), and height (H) of thearticle are shown in FIG. 3 to correspond to measurements in the x-, y-,and z-directions, respectively, and are measured according to the Widthand Length Test Method and the Height Test Method described herein.

As shown in FIG. 4, another example of an article 20, for example afibrous structure according to the present invention comprises a firstfibrous structure layer or ply 22 comprising a plurality of fibrouselements, for example filaments 10, a second fibrous structure layer 24comprising a plurality of fibrous elements, for example filaments 10,and a plurality of particles or a particle layer 26 positioned betweenthe first and second fibrous structure layers 22 and 24. A similarfibrous structure can be formed by depositing a plurality of particleson a surface of a first ply of fibrous structure comprising a pluralityof fibrous elements and then associating a second ply of fibrousstructure comprising a plurality of fibrous elements such that theparticles or a particle layer are positioned between the first andsecond fibrous structure plies.

As shown in FIG. 5, another example of an article 20, for example afibrous structure of the present invention comprises a first fibrousstructure layer 22 comprising a plurality of fibrous elements, forexample filaments 10, wherein the first fibrous structure layer 22comprises one or more pockets 28 (also referred to as recesses, unfilleddomes, or deflected zones), which may be in an irregular pattern or anon-random, repeating pattern. One or more of the pockets 28 may containone or more particles 26. The article 20 in this example furthercomprises a second fibrous structure layer 24 that is associated withthe first fibrous structure layer 22 such that the particles 26 areentrapped in the pockets 28. Like above, a similar article can be formedby depositing a plurality of particles in pockets of a first ply offibrous structure comprising a plurality of fibrous elements and thenassociating a second ply of fibrous structure comprising a plurality offibrous elements such that the particles are entrapped within thepockets of the first ply. In one example, the pockets may be separatedfrom the fibrous structure to produce discrete pockets.

As shown in FIG. 6, another example of an article 20, for example amulti-ply fibrous structure of the present invention comprises a firstply 30 of a fibrous structure according to FIG. 5 above and a second ply32 of fibrous structure associated with the first ply 30, wherein thesecond ply 32 comprises a plurality of fibrous elements, for examplefilaments 10, and a plurality of particles 26 dispersed, in this caserandomly, in the x, y, and z axes, throughout the article 20.

As shown in FIG. 7, another example of an article 20, for example afibrous structure of the present invention comprises a plurality offibrous elements, for example filaments 10, such as activeagent-containing filaments, and a plurality of particles 26, for exampleactive agent-containing particles, dispersed, in this case randomly, inthe x, y, and z axes, throughout the fibrous structure of the article20.

As shown in FIG. 8, another example of an article 20, for example afibrous structure of the present invention comprises a first fibrousstructure layer 22 comprising a plurality of fibrous elements, forexample filaments 10, and a second fibrous structure layer 24 comprisinga plurality of fibrous elements, for example filaments 10, for exampleactive agent-containing filaments, and a plurality of particles 26, forexample active agent-containing particles, dispersed, in this caserandomly, in the x, y, and z axes, throughout the second fibrousstructure layer 24. Alternatively, in another example, the plurality ofparticles 26, for example active agent-containing particles, may bedispersed in an irregular pattern or a non-random, repeating patternwithin the second fibrous structure layer 24. Like above, a similararticle comprising two plies of fibrous structure comprising a firstfibrous structure ply 22 comprising a plurality of fibrous elements, forexample filaments 10, and a second fibrous structure ply 24 comprising aplurality of fibrous elements, for example filaments 10, for exampleactive agent-containing filaments, and a plurality of particles 26, forexample active agent-containing particles, dispersed, in this caserandomly, in the x, y, and z axes, throughout the second fibrousstructure ply 24. Alternatively, in another example, the plurality ofparticles 26, for example active agent-containing particles, may bedispersed in an irregular pattern or a non-random, repeating patternwithin the second fibrous structure ply 24.

FIG. 9 shows another example of an article 20, for example a multi-plyfibrous structure of the present invention comprising a first ply 30 ofa fibrous structure as shown in FIG. 8 comprising a first fibrousstructure layer 22 comprising a plurality of fibrous elements, forexample filaments 10, and a second fibrous structure layer 24 comprisinga plurality of fibrous elements, for example filaments 10, for exampleactive agent-containing filaments, and a plurality of particles 26, forexample active agent-containing particles, dispersed, in this caserandomly, in the x, y, and z axes, throughout the second fibrousstructure layer 24, a second ply 32 of a fibrous structure associatedwith the first ply 30, wherein the second ply 32 comprises a firstfibrous structure layer 22 comprising a plurality of fibrous elements,for example filaments 10, and a second layer 24 comprising a pluralityof fibrous elements, for example filaments 10, for example activeagent-containing filaments, and a plurality of particles 26, for exampleactive agent-containing particles, dispersed, in this case randomly, inthe x, y, and z axes, throughout the second fibrous structure layer 24,and a third ply 34 of a fibrous structure associated with the second ply32, wherein the third ply 34 comprises a first fibrous structure layer22 comprising a plurality of fibrous elements, for example filaments 10,and a second fibrous structure layer 24 comprising a plurality offibrous elements, for example filaments 10, for example activeagent-containing filaments, and a plurality of particles 26, for exampleactive agent-containing particles, dispersed, in this case randomly, inthe x, y, and z axes, throughout the second fibrous structure layer 24.

As shown in FIG. 10, another example of an article 20, for example amulti-ply fibrous structure of the present invention comprises a firstply 30 of a fibrous structure comprising a plurality of fibrouselements, for example filaments 10, a second ply 32 of a fibrousstructure associated with the first ply 30, wherein the second ply 32comprises a plurality of fibrous elements, for example filaments 10, anda third ply 34 of a fibrous structure associated with the second ply 32,wherein the third ply 34 comprises a plurality of fibrous elements, forexample filaments 10. In one example of FIG. 10, each ply's filaments 10may comprise active agent-containing filaments.

FIG. 11 shows another example of an article 20 multi-ply fibrousstructure 20 of the present invention comprising a first ply 30 of afibrous structure comprising a plurality of fibrous elements, forexample filaments 10, a second ply 32 of fibrous structure comprising aplurality of fibrous elements, for example filaments 10, a third ply 34of a fibrous structure comprising a plurality of fibrous elements, forexample filaments 10, a fourth ply 36 of fibrous structure comprising aplurality of fibrous elements, for example filaments 10, and a fifth ply38 of a fibrous structure comprising a plurality of fibrous elements,for example filaments 10. In this example, the article 20 furthercomprises one or more particles or particle layers 26 positioned betweenat least two adjacent fibrous structure plies, for example plies 30 and32 or plies 32 and 34 or plies 34 and 36 or plies 36 and 38. The plies30, 32, 34, 36, and 38 are associated with one or more other plies toform a unitary structure and to minimize particles 26, if any arepresent within the article 20, from becoming disassociated from thearticle 20. In another example, the one or more particles or particlelayers 26 positioned between at least two adjacent fibrous structureplies are present in an irregular pattern, a non-random, repeatingpattern, or only in select zones between the plies.

As shown in FIG. 12, another example of an article 20, for example afilm structure of the present invention comprises a film structurecomprising one or more active agents.

As shown in FIG. 13, another example of an article 20, for example amulti-ply film structure of the present invention comprises a first ply30 of a film structure and a second ply 32 of a film structureassociated with the first ply 30, wherein at least one of the first andsecond plies 30, 32 comprise one or more active agents. In one example,both the first and second plies 30, 32 comprise one or more activeagents, which may be the same or different between the two plies 30, 32.

As described above, in certain examples, the article can besubstantially formed from non-filament containing structures. In certainexamples, the article can be entirely formed from non-filamentcontaining structures. In such examples, the article can include one ormore active agents releasable therefrom. Further, the article can be amulti-ply article including two or more plies, where surfaces of the twoor more plies are substantially in contact with each other along eitherthe length or width of the article. In certain examples, the article caninclude about 90% or more and/or about 92% or more and/or about 95% ormore and/or about 97% or more and/or about 98% or more and/or about 99%or more and/or about 100% by weight of one or more active agentsreleasable therefrom when exposed to conditions of intended use, forexample when exposed to conditions experienced in an automatic clothesdryer and/or in a washing machine. It will be appreciated that sucharticles can exhibit the consumer-preferred properties and possess thearticle dimensions in accordance with those described herein. In certainexamples, the non-filament article can be substantially free of fluid.

With respect to an article including one or more fibrous elements, thefibrous elements and/or fibrous structures of the present invention arein solid form. However, the filament-forming composition used to makethe fibrous elements of the present invention may be in the form of aliquid.

In one example, the fibrous structure comprises a plurality of identicalor substantially identical from a compositional perspective of fibrouselements according to the present invention.

In another example, the fibrous structure may comprise two or moredifferent fibrous elements according to the present invention.Non-limiting examples of differences in the fibrous elements may bephysical differences such as differences in diameter, length, texture,shape, rigidness, elasticity, and the like; chemical differences such ascrosslinking level, solubility, melting point, Tg, active agent,filament-forming material, color, level of active agent, basis weight,level of filament-forming material, presence of any coating on fibrouselement, biodegradable or not, hydrophobic or not, contact angle, andthe like; differences in whether the fibrous element loses its physicalstructure when the fibrous element is exposed to conditions of intendeduse; differences in whether the fibrous element's morphology changeswhen the fibrous element is exposed to conditions of intended use; anddifferences in rate at which the fibrous element releases one or more ofits active agents when the fibrous element is exposed to conditions ofintended use. In one example, two or more fibrous elements and/orparticles within the fibrous structure may comprise different activeagents. This may be the case where the different active agents may beincompatible with one another, for example an anionic surfactant (suchas a shampoo active agent) and a cationic surfactant (such as a hairconditioner active agent).

In another example, the fibrous structure may exhibit different regions,such as different regions of basis weight, density and/or caliper. Inyet another example, the fibrous structure may comprise texture on oneor more of its surfaces. A surface of the fibrous structure may comprisea pattern, such as a non-random, repeating pattern. The fibrousstructure may be embossed with an emboss pattern. In another example,the fibrous structure may comprise apertures. The apertures may bearranged in a non-random, repeating pattern.

In one example, the fibrous structure may comprise discrete regions offibrous elements that differ from other parts of the fibrous structure.

The fibrous structure of the present invention may be used as is or maybe coated with one or more active agents.

Particles

The particles may be water-soluble or water-insoluble. In one example,one group of particles may be water-soluble and a different group ofparticles may be water-insoluble. The particles, water-soluble orwater-insoluble, may themselves deliver a benefit to the consumer. Inanother example, the particles, water-soluble or water-insoluble, maycomprise one or more active agents (in other words, the particles maycomprises active agent-containing particles). In still another example,the particles may consist essentially of and/or consist of one or moreactive agents (in other words, the particles, water-soluble and/orwater-insoluble, may comprise 100% or greater than about 100% by weighton a dry particle basis of one or more active agents). In still anotherexample, the particles may comprise water-soluble particles. In yetanother example, the particles may comprise water-soluble, activeagent-containing particles. In one other example, the water-insolubleparticles comprise zeolites, porous zeolites, perfume-loaded zeolites,active loaded zeolites, silicas, perfume-loaded silicas, active loadedsilicas, perfume microcapsules, clays, and mixtures thereof.

Fibrous Elements

The fibrous elements of the present invention are water-insoluble. Inone example, the fibrous elements comprise one or more active agentsthat are releasable from the fibrous element, such as when the fibrouselement and/or fibrous structure comprising the fibrous element isexposed to conditions of intended use. In addition to the one or moreactive agents, the fibrous elements may comprise one or more activeagents.

In one example, the total level of the one or more active agents presentin the fibrous elements and/or film structures and/or articles is 80% orgreater and/or greater than 85% and/or greater than 90% and/or greaterthan 95% and/or greater than 96% and/or greater than 97% and/or greaterthan 98% and/or greater than 99% and/or about 100% by weight on a dryfibrous element and/or dry film structure and/or dry fibrous structureand/or dry article basis. In one example, one or more auxiliaryingredients, for example one or more filament-forming materials, such asone or more structurants, may be present in the fibrous elements and/orfilm structures and/or articles at a total level of 20% or less and/orless than 15% and/or less than 10% and/or less than 5% and/or less than4% and/or less than 3% and/or less than 2% and/or less than 1% and/orabout 0% by weight on a dry fibrous element and/or dry film structureand/or dry fibrous structure and/or dry article basis.

In one example, the fibrous element exhibits a diameter of less than 100μm and/or less than 75 μm and/or less than 50 μm and/or less than 25 μmand/or less than 10 μm and/or less than 5 μm and/or less than 1 μm asmeasured according to the Diameter Test Method described herein. Inanother example, the fibrous element of the present invention exhibits adiameter of greater than 1 μm as measured according to the Diameter TestMethod described herein. The diameter of a fibrous element of thepresent invention may be used to control the rate of release of one ormore active agents present in the fibrous element and/or the rate ofloss and/or altering of the fibrous element's physical structure.

The fibrous element may comprise two or more different active agents. Inone example, the fibrous element comprises two or more different activeagents, wherein the two or more different active agents are compatiblewith one another. In another example, the fibrous element comprises twoor more different active agents, wherein the two or more differentactive agents are incompatible with one another.

In one example, the fibrous element may comprise an active agent withinthe fibrous element and an active agent on an external surface of thefibrous element, such as an active agent coating on the fibrous element.The active agent on the external surface of the fibrous element may bethe same or different from the active agent present in the fibrouselement. If different, the active agents may be compatible orincompatible with one another.

In another example, the fibrous structure or article of the presentinvention may comprise a coating on the external fibrous elements orfilaments on one of the surfaces of the plies of the article. Thecoating may be applied to a surface of a ply and the surface with thecoating may be an outer surface of the overall article or may be asurface internal to the article. Placement of the coating depends uponthe benefit or active agent desired to be delivered. For example,coatings on an outer surface ply of the article would be more readilyvisible to a consumer, as it is on a consumer viewable surface. Acoating on internal surface ply of the article may be less visible, asit may be hidden from direct view by a consumer. Placement of thecoating on an internal surface and/or an outer surface of the articlewill be achieved as part of the article making process. A coating on aninternal surface ply may be different or the same as coatings on theouter surface of the article. In one example, an article may havecoatings on outer surfaces and/or internal surfaces of the article. Inanother example, an article may have coatings on outer surfaces and/orinternal surfaces of plies making up the article. In yet anotherexample, an article may have a silicone active agent comprising acoating or an aminosilicone comprising a coating on outer surfacesand/or internal surfaces of plies making up the article.

In one example, one or more active agents may be uniformly distributedor substantially uniformly distributed throughout the fibrous element.In another example, one or more active agents may be distributed asdiscrete regions within the fibrous element. In still another example,at least one active agent is distributed uniformly or substantiallyuniformly throughout the fibrous element and at least one other activeagent is distributed as one or more discrete regions within the fibrouselement. In still yet another example, at least one active agent isdistributed as one or more discrete regions within the fibrous elementand at least one other active agent is distributed as one or morediscrete regions different from the first discrete regions within thefibrous element.

Active Agents

Non-limiting examples of suitable active agents for use in the fibrouselements and/or films and/or articles of the present invention includedryer added active agents, such as fabric conditioning active agents,and/or hair care conditioning active agents. As used herein a “fabricconditioning active agent” means any material that performs a functionor delivers a benefit, such as modifying the physical or chemicalproperties of a treated material (e.g., fabric). Even though thedescription relates primarily to treating fabrics, the fabricconditioning active agents may also provide benefits, such asconditioning benefits to hair (e.g., hair conditioning active agents).Non-limiting examples of suitable fabric conditioning active agentsand/or hair conditioning active agents include: perfumes, fabricconditioning agents, anti-static agents, crisping agents, water/stainrepellents, stain release agents, refreshing agents, disinfectingagents, wrinkle resistance agents, wrinkle release agents, odorresistance agents, malodor control agents, abrasion resistance andprotection agents, solvents, insect/pet repellents, wetting agents, UVprotection agents, skin/fabric conditioning agents, skin/fabricnurturing agents, skin/fabric hydrating agents, color protection agents,dye fixatives, dye transfer inhibiting agents, silicones, preservativesand anti-microbials, fabric shrinkage-reducing agents, brighteners,hueing dyes, bleaches, chelants, antifoams, anti-scum agents, whiteningagents, catalysts, cyclodextrin, zeolite, petrolatum, glycerin,triglycerides, vitamins, other skin care actives such as aloe vera,chamomile, shea butter and the like, mineral oils, and mixtures thereof.In one example, the articles of the present invention comprise one ormore fabric conditioning active agents for imparting one or more fabriccare benefits such as softening, anti-static, color protection, etc., tofabrics. In another example, the articles of the present invention maycomprise one or more fabric conditioning active agents selected from thegroup consisting of: perfumes, builders, chelants, antioxidants,brighteners, sun fade inhibiting agents, UV absorbing agents, insectrepellants, scents, bleaching agents, enzymes, antimicrobials,antibacterials, antifungals, perfume delivery systems, perfumemicrocapsules, dye transfer inhibiting agents, hueing dyes, soil releaseagents, such as soil release polymers, for example soil release polymerthat comprise copolymeric blocks of terephthalate and polyethylene oxideor polypropylene oxide, and cationic soil release agents, colorants,preservatives, opacifiers, stabilizers such as guar gum and polyethyleneglycol, anti-shrinkage agents, anti-wrinkle agents, soil release agents,fabric crisping agents, reductive agents, spotting agents, germicides,fungicides, anti-corrosion agents, and mixtures thereof. In one example,the articles of the present invention comprise one or more hairconditioning active agents for imparting one or more hair care benefitssuch as softening, anti-static, color protection, etc. to hair. Inanother example, the articles of the present invention may comprise oneor more active agents selected from the group consisting of: fabric careactive agents, dishwashing active agents, carpet care active agents,surface care active agents, hair care active agents, air care activeagents, oral care active agents, dryer added active agents, and mixturesthereof.

In one example, the articles of the present invention comprise one ormore fabric conditioning active agents and/or hair conditioning activeagents selected from the group consisting of: fatty fabric conditioningactive agents (for example fatty acids and/or fatty acid derivativesand/or fatty alcohols), sulfonic acid derivatives, quaternary ammoniumcompounds, tertiary amines and salts thereof, nonionic surfactants, andmixtures thereof.

In one example, the fabric conditioning active agent and/or hairconditioning active agents comprises, alone or in combination with oneor more fatty fabric conditioning active agents and/or fatty hairconditioning active agents (for example one or more fatty acids and/orone or more fatty alcohols), one or more quaternary ammonium compoundsselected from the group consisting of:di(tallowyloxyethyl)hydroxyethylmethylammoniummethylsulfate, dimethylbis(stearoyl oxyethyl)ammonium chloride, dimethylbis(tallowyloxyethyl)ammonium chloride, dimethylbis(tallowyloxyisopropyl)ammonium methylsulfate and mixtures thereof.

In one example, the fabric conditioning active agent and/or hairconditioning active agent comprises, alone or in combination with one ormore quaternary ammonium compounds and/or one or more fatty alcohols,one or more fatty acids selected from the group consisting of: myristicacid, stearic acid, isostearic acid, cetearic acid, dodecanoic acid,linoleic acid, oleic acid, palmitic acid, lauric acid, and mixturesthereof.

In one example, the fabric conditioning active agent and/or hairconditioning active agent comprises, alone or in combination with one ormore quaternary ammonium compounds and/or one or more fatty acids, oneor more fatty alcohols selected from the group consisting of: cetylalcohol, stearyl alcohol, behenyl alcohol, lauryl alcohol, myristicalcohol, isostearyl alcohol, arachidyl alcohol, and mixtures thereof.

Quaternary Ammonium Compounds

In one example, the fabric conditioning active agent and/or hairconditioning active agents comprises one or more fatty alcohols and oneor more quaternary ammonium compounds. In one example, the article ofthe present invention comprises one or more fatty alcohols and one ormore quaternary ammonium compounds in a weight ratio of greater than 1:1and/or greater than 1.5:1 and/or greater than 1.75:1 and/or greater than1.9:1.

In one example, the fabric conditioning active agent and/or hairconditioning active agent comprises one or more fatty acids and one ormore quaternary ammonium compounds. In one example, the article of thepresent invention comprises one or more fatty acids and one or morequaternary ammonium compounds in a weight ratio of greater than 1:1and/or greater than 1.5:1 and/or greater than 1.75:1 and/or greater than1.9:1.

In one example, the fabric conditioning active agent and/or hairconditioning active agent comprises a quaternary ammonium compound.Non-limiting examples of quaternary ammonium compounds include alkylatedquaternary ammonium compounds, ring or cyclic quaternary ammoniumcompounds, aromatic quaternary ammonium compounds, diquaternary ammoniumcompounds, alkoxylated quaternary ammonium compounds, amidoaminequaternary ammonium compounds, ester quaternary ammonium compounds, andmixtures thereof. See U.S. Patent Pub. 2005/0192207 at 57-66. The fabricconditioning active agents and/or hair conditioning active agents can beone or a mixture of a quaternary ammonium compound, a tertiary amine andor its salts, an ethoxylated fatty material, a fatty acid or a mixturethereof. Non-limiting examples of fabric conditioning active agents thatare especially useful in the articles of the present invention aredescribed in U.S. Pat. No. 4,103,047, Zaki et al., issued Jul. 25, 1978;U.S. Pat. No. 4,237,155, Kardouche, issued Dec. 2, 1980; U.S. Pat. No.3,686,025, Morton, issued Aug. 22, 1972; U.S. Pat. No. 3,849,435, Dieryet al., issued Nov. 19, 1974: and U.S. Pat. No. 4,073,996, Bedenk,issued Feb. 14, 1978; said patents are hereby incorporated herein byreference. Other fabric conditioning active agents and/or hairconditioning active agents are disclosed hereinafter.

Non-limiting examples of suitable quaternary ammonium compounds includecationic fabric conditioning active agents and/or cationic hairconditioning active agents and their salts such as dialkyldimethylammonium chlorides, methylsulfates and ethylsulfates wherein thealkyl groups can be the same or different and contain from about 12 toabout 22 carbon atoms. Non-limiting examples of such cationic fabricconditioning active agents and/or cationic hair conditioning activeagents include ditallowalkyldimethylammonium methylsulfate (DTDMAMS),distearyldimethylammonium methylsulfate, dipalmityldimethylammoniummethylsulfate and dibehenyldimethylammonium methylsulfate.

Another example of a suitable fabric conditioning active agent and/orhair conditioning active agents is an ester quaternary ammonium compound(EQA) selected from Formulas IA, IB, II, III, IV, and mixtures thereof.

Formula IA comprises:[(R¹)_(4-p) _(.) —N⁺—((CH₂)_(v)—Y—R²)^(p)]X⁻

wherein each Y=—O—(O)C—, or —C(O)—O—; p=1 to 3; each v=is an integerfrom 1 to 4, and mixtures thereof; each R¹ substituent is a short chainC₁-C₆, and/or C₁-C₃, alkyl group, e.g., methyl, ethyl, propyl, and thelike, benzyl and mixtures thereof; each R² is a long chain, saturatedand/or unsaturated (Iodine Value of from about 3 to about 60), C₈-C₃₀hydrocarbyl, or substituted hydrocarbyl substituent and mixturesthereof; and the counterion, X⁻, can be any softener-compatible anion,for example, methylsulfate, ethylsulfate, chloride, bromide, formate,sulfate, lactate, nitrate, benzoate, and the like, such asmethylsulfate.

It will be understood that substituents R¹ and R² of Formula IA canoptionally be substituted with various groups such as alkoxyl orhydroxyl groups. In one example, Formula IA compounds are diesterquaternary ammonium salts (DEQA). At least about 25% of the DEQA is inthe diester form, and from 0% to about 40% and/or less than about 30%and/or less than about 20%, can be EQA monoester (e.g., only one —Y—R²group).

Formula IB comprises:[(R¹)_(4-p)—N⁺—((CH₂CHR³)_(v)—Y—R²)_(p)]X⁻

wherein each Y=—O—(O)C—, or —C(O)—O—; p=1 to 3; each v=is an integerfrom 1 to 4, and mixtures thereof; each R¹ substituent is a short chainC₁-C₆, and/or C₁-C₃, alkyl group, e.g., methyl, ethyl, propyl, and thelike, benzyl and mixtures thereof; each R² is a long chain, saturatedand/or unsaturated (Iodine Value of from about 3 to about 60), C₈-C₃₀hydrocarbyl, or substituted hydrocarbyl substituent and mixturesthereof; each R³ substituent is a short chain C₁-C₆ including benzyl,and/or C₁-C₃ alkyl group e.g., methyl, ethyl, propyl, and/or C₁-C₂ e.g.,methyl, ethyl, and mixtures thereof; and the counterion, X⁻, can be anysoftener-compatible anion, for example, methylsulfate, ethylsulfate,chloride, bromide, formate, sulfate, lactate, nitrate, benzoate, and thelike, such as methylsulfate.

It will be understood that substituents R¹ and R² of Formula IB canoptionally be substituted with various groups such as alkoxyl orhydroxyl groups. In one example, Formula IB compounds are diesterquaternary ammonium salts (DEQA). At least about 25% of the DEQA is inthe diester form, and from 0% to about 40% and/or less than about 30%and/or less than about 20%, can be EQA monoester (e.g., only one —Y—R²group).

As used herein, when the diester is specified, it will include themonoester that is normally present. For the optimal antistatic benefitthe percentage of monoester should be as low as possible, such as lessthan about 2.5%. The level of monoester present can be controlled in themanufacturing of the EQA.

EQA compounds prepared with fully saturated acyl groups are excellentsofteners. However, it has now been discovered that compounds preparedwith at least partially unsaturated acyl groups have advantages (i.e.,anti-static benefits) and are highly acceptable for consumer productswhen certain conditions are met. Variables that must be adjusted toobtain the benefits of using unsaturated acyl groups include the IodineValue of the fatty acids, the odor of fatty acid starting material,and/or the EQA. Any reference to Iodine Value values hereinafter refersto Iodine Value of fatty acyl groups and not to the resulting EQAcompound.

Some highly desirable, readily available sources of fatty acids such astallow, possess odors that remain with the compound EQA despite thechemical and mechanical processing steps which convert the raw tallow tofinished EQA. Such sources must be deodorized, e.g., by absorption,distillation (including stripping such as steam stripping), etc., as iswell known in the art. In addition, care must be taken to minimizecontact of the resulting fatty acyl groups to oxygen and/or bacteria byadding antioxidants, antibacterial agents, etc.

Generally, hydrogenation of fatty acids to reduce polyunsaturation andto lower Iodine Value to insure good color and odor stability leads to ahigh degree of trans configuration in the molecule. Therefore, diestercompounds derived from fatty acyl groups having low Iodine Value valuescan be made by mixing fully hydrogenated fatty acid with touchhydrogenated fatty acid at a ratio which provides an Iodine Value offrom about 3 to about 60. The polyunsaturation content of the touchhardened fatty acid should be less than about 5% and/or less than about1%. During touch hardening the cis/trans isomer weight ratios arecontrolled by methods known in the art such as by optimal mixing, usingspecific catalysts, providing high H₂ availability, etc.

It has been found that a solvent may be used to facilitate processing ofthe Formula IA and/or IB EQA and/or of the fabric conditioningcomposition containing the EQA Formula IA and/or IB.

It has also been found that for good chemical stability of the diesterquaternary compound in molten storage, water levels in the raw materialmust be minimized, for example to less than about 8% and/or less thanabout 5%. Storage temperatures should be kept as low as possible andstill maintain a fluid material, ideally in the range of from about 45°C. to about 70° C. The optimum storage temperature for stability andfluidity depends on the specific Iodine Value of the fatty acid used tomake the diester quaternary and the level/type of solvent selected.Also, exposure to oxygen should be minimized to keep the unsaturatedgroups from oxidizing. It can therefore be important to store thematerial under a reduced oxygen atmosphere such as a nitrogen blanket.It is important to provide good molten storage stability to provide acommercially feasible raw material that will not degrade noticeably inthe normal transportation/storage/handling of the material inmanufacturing operations.

The following are non-limiting examples of EQA Formula IA or IB (whereinall long-chain alkyl substituents are straight-chain):

Saturated

where —C(O)R² is derived from saturated tallow.

Unsaturated

where —C(O)R² is derived from partially hydrogenated tallow or modifiedtallow having the characteristics set forth herein.

In addition to Formula IA and IB compounds, the compositions andarticles of the present invention comprise EQA compounds of Formula II:

wherein, for any molecule: each Q is —O—C(O)— or —C(O)—O—; each R¹ isC₁-C₄ alkyl or hydroxy alkyl; R² and v are defined hereinbefore forFormula IA and IB; for example wherein R¹ is a methyl group, v is 1, Qis —O—C(O)—, each R² is C₁₄-C₁₈, and X⁻ is methyl sulfate.

The straight or branched alkyl or alkenyl chains, R², have from about 8to about 30 carbon atoms and/or from about 14 to about 18 carbon atomsand/or straight chains having from about 14 to about 18 carbon atoms.

Tallow is a convenient and inexpensive source of long chain alkyl andalkenyl materials.

A specific example of a Formula II EQA compound suitable for use as afabric conditioning active agent and/or hair conditioning active agentherein is: 1,2-bis(tallowyl oxy)-3-trimethyl ammoniopropanemethylsulfate (DTTMAPMS).

Other examples of suitable Formula II EQA compounds of this inventionare obtained by, e.g., replacing “tallowyl” in the above compounds with,for example, cocoyl, lauryl, oleyl, stearyl, palmityl, or the like;replacing “methyl” in the above compounds with ethyl, propyl, isopropyl,butyl, isobutyl, t-butyl, or the hydroxy substituted analogs of theseradicals; and/or replacing “methylsulfate” in the above compounds withchloride, ethylsulfate, bromide, formate, sulfate, lactate, nitrate, andthe like, for example methylsulfate.

In addition to Formula IA and IB and Formula II compounds, the articlesof the present invention may comprise EQA compounds of Formula III:

wherein R⁴=a short chain C₁-C₄ alcohol; p is 2; R¹, R², v, Y, and X⁻ areas previously defined for Formula IA and IB.

A specific example of a Formula III compound suitable for use as afabric conditioning active agent and/or hair conditioning active agentherein is N-methyl-N,N-di-(2-(C₁₄-C₁₈-acyloxy) ethyl), N-2-hydroxyethylammonium methylsulfate. An example of such as compound is N-methyl,N,N-di-(2-oleyloxyethyl)N-2-hydroxyethyl ammonium methylsulfate.

Fabric conditioning active agents and/or hair conditioning active agentsof the present invention may also comprise Formula IV compounds:[(R¹)_(4-p) _(.) —N⁺—((CH₂)_(v)—Y″—R²)_(p)]X⁻wherein R¹, R², p, v, and X⁻ are previously defined in Formula IA andIB; and[(R¹)_(4-p) _(.) —N⁺—((CH₂)_(v)—Y—R²)_(p)]X⁻and mixtures thereof, wherein at least one Y″ group is

An example of this compound is methyl bis (oleyl amidoethyl)2-hydroxyethyl ammonium methyl sulfate.

In one example, the fabric conditioning active agent and/or hairconditioning active agent of the present invention is a quaternaryammonium compound.

The compounds herein can be prepared by standard esterification andquaternization reactions, using readily available starting materials.General methods for preparation are disclosed in U.S. Pat. No.4,137,180, which is incorporated herein by reference.

Tertiary Amines and Salts Thereof

Another fabric conditioning active agent and/or hair conditioning activeagent useful in the fibrous elements and/or films and/or articles of thepresent invention is a carboxylic acid salt of a tertiary amine and/orester amine having the formula:

wherein R⁵ is a long chain aliphatic group containing from about 8 toabout 30 carbon atoms; R⁶ and R⁴ are the same or different from eachother and are selected from the group consisting of aliphatic groupscontaining from about 1 to about 30 carbon atoms, hydroxyalkyl groups ofthe Formula R⁸OH wherein R⁸ is an alkylene group of from about 2 toabout 30 carbon atoms, and alkyl ether groups of the formulaR⁹O(C_(n)H_(2n)O)_(m) wherein R⁹ is alkyl and alkenyl of from about 1 toabout 30 carbon atoms and hydrogen, n is 2 or 3, and m is from about 1to about 30; wherein R⁴, R⁵, R⁶, R⁸, and R⁹ chains can be esterinterrupted groups; and wherein R⁷ is selected from the group consistingof unsubstituted alkyl, alkenyl, aryl, alkaryl and aralkyl of about 8 toabout 30 carbon atoms, and substituted alkyl, alkenyl, aryl, alkaryl,and aralkyl of from about 1 to about 30 carbon atoms wherein thesubstituents are selected from the group consisting of halogen,carboxyl, and hydroxyl, said composition having a thermal softeningpoint of from about 35° C. to about 100° C.

The tertiary amine and/or ester amine can provide superior odor and/orimproved fabric conditioning performance, compared to similar articleswhich utilize primary amine or ammonium compounds as the sole fabricconditioning active agent and/or hair conditioning active agent. EitherR⁴, R⁵, R⁶, R⁷, R⁸, and/or R⁹ chains can contain unsaturation.

In one example, R⁵ is an aliphatic chain containing from about 12 toabout 30 carbon atoms, R⁶ is an aliphatic chain of from about 1 to about30 carbon atoms, and R⁴ is an aliphatic chain of from about 1 to about30 carbon atoms. In one example, suitable tertiary amines for staticcontrol performance are those containing unsaturation; e.g.,oleyldimethylamine and/or soft tallowdimethylamine.

Examples of suitable tertiary amines as starting material for thereaction between the amine and carboxylic acid to form the tertiaryamine salts are: lauryldimethylamine, myristyldimethyl-amine,stearyldimethylamine, tallowdimethylamine, coconutdimethylamine,dilaurylmethylamine, distearylmethylamine, ditallowmethylamine,oleyldimethylamine, dioleylmethylamine, lauryldi(3-hydroxypropyl)amine,stearyldi(2-hydroxyethyl)amine, trilaurylamine, laurylethylmethylamine,and

Non-limiting examples of suitable fatty acids are those wherein R⁷ is along chain, unsubstituted alkyl or alkenyl group of from about 8 toabout 30 carbon atoms and/or from about 11 to about 17 carbon atoms.

Examples of specific carboxylic acids as a starting material are: formicacid, acetic acid, lauric acid, myristic acid, palmitic acid, stearicacid, oleic acid, oxalic acid, adipic acid, 12-hydroxy stearic acid,benzoic acid, 4-hydroxy benzoic acid, 3-chloro benzoic acid, 4-nitrobenzoic acid, 4-ethyl benzoic acid, 4-(2-chloroethyl)benzoic acid,phenylacetic acid, (4-chlorophenyl)acetic acid, (4-hydroxyphenyl)aceticacid, and phthalic acid.

Non-limiting examples of suitable carboxylic acids are stearic, oleic,lauric, myristic, palmitic, and mixtures thereof.

The amine salt can be formed by a simple addition reaction, well knownin the art and disclosed in U.S. Pat. No. 4,237,155, Kardouche, issuedDec. 2, 1980, which is incorporated herein by reference. Excessivelevels of free amines may result in odor problems, and generally freeamines provide poorer softening performance than the amine salts.

Non-limiting examples of amine salts for use herein are those whereinthe amine moiety is a C₈-C₃₀ alkyl or alkenyl dimethyl amine and/or adi-C₈-C₃₀ alkyl or alkenyl methyl amine, and the acid moiety is a C₈-C₃₀alkyl and/or alkenyl monocarboxylic acid. The amine and the acid,respectively, used to form the amine salt will often be of mixed chainlengths rather than single chain lengths, since these materials arenormally derived from natural fats and oils, or synthetic processedwhich produce a mixture of chain lengths. Also, it is often desirable toutilize mixtures of different chain lengths in order to modify thephysical or performance characteristics of the softening composition.

Specific examples of amine salts for use in the present invention areoleyldimethylamine stearate, stearyldimethylamine stearate,stearyldimethylamine myristate, stearyldimethylamine oleate,stearyldimethylamine palmitate, distearylmethylamine palmitate,distearylmethylamine laurate, and mixtures thereof. In one example, amixture of amine salts is oleyldimethylamine stearate anddistearylmethylamine myristate, in a ratio of 1:10 to 10:1 and/or about1:1.

Sulfonic Acid Fatty Amine Salts

Other fatty amine salts can be used in the present invention. Thesesalts are similar to those previously described but replacing thecarboxylic acid with a sulfonic acid derivative. The amine salt can beformed by a simple addition reaction, well known in the art anddisclosed in U.S. Pat. No. 4,861,502, Caswell issued Aug. 29, 1989,which is incorporated herein by reference. Such sulfonic acid derivatesinclude but not limited to methylsulfonic acid, benzenesulfonic acid,toluensulfonic acid, cumenesulfonic and mixtures thereof.

Nonionic Fabric Conditioning Active Agents and/or Hair ConditioningActive Agents

Non-limiting examples of suitable nonionic fabric conditioning activeagents and/or nonionic hair conditioning active agents for use in thefibrous elements and/or films and/or articles of the present inventionhave an HLB of from about 2 to about 9, and more typically from about 3to about 7. In general, the materials selected should be relativelycrystalline and higher melting, (e.g., >25° C.).

The level of optional nonionic fabric conditioning active agents and/oroptional nonionic hair conditioning active agents in the article istypically from about 0.1% to about 50% and/or from about 5% to about30%.

Non-limiting examples of suitable nonionic fabric conditioning activeagents and/or nonionic hair conditioning active agents are fatty acidpartial esters of polyhydric alcohols, or anhydrides thereof, whereinthe alcohol or anhydride contains from about 2 to about 18 and/or fromabout 2 to about 8 carbon atoms, and each fatty acid moiety containsfrom about 8 to about 30 and/or from about 12 to about 20 carbon atoms.Typically, such nonionic fabric conditioning active agents and/or hairconditioning active agents contain from about one to about 3 and/orabout 2 fatty acid groups per molecule.

The polyhydric alcohol portion of the ester can be ethylene glycol,glycerol, poly (e.g., di-tri-, tetra, penta-, and/or hexa-) glycerol,xylitol, sucrose, erythritol, pentaerythritol, sorbitol or sorbitan.

The fatty acid portion of the ester is normally derived from fatty acidshaving from about 8 to about 30 and/or from about 12 to about 22 carbonatoms. Typical examples of said fatty acids being lauric acid, myristicacid, palmitic acid, stearic acid, oleic acid, and behenic acid.

Non-limiting example of suitable nonionic fabric conditioning activeagents and/or hair conditioning active agents for use in the presentinvention are C₁₀-C₂₆ acyl sorbitan esters and polyglycerolmonostearate. Sorbitan esters are esterified dehydration products ofsorbitol. The sorbitan ester may comprise a member selected from thegroup consisting of C₁₀-C₂₆ acyl sorbitan monoesters and/or C₁₀-C₂₆ acylsorbitan diesters and/or ethoxylates of said esters wherein one or moreof the unesterified hydroxyl groups in said esters contains from about 1to about 6 oxyethylene units, and mixtures thereof. For the purpose ofthe present invention, sorbitan esters containing unsaturation (e.g.,sorbitan monooleate) can be utilized.

Sorbitol, which is typically prepared by the catalytic hydrogenation ofglucose, can be dehydrated in well-known fashion to form mixtures of1,4- and 1,5-sorbitol anhydrides and small amounts of isosorbides. (SeeU.S. Pat. No. 2,322,821, Brown, issued Jun. 29, 1943, incorporatedherein by reference.)

The foregoing types of complex mixtures of anhydrides of sorbitol arecollectively referred to herein as “sorbitan.” It will be recognizedthat this “sorbitan” mixture will also contain some free, uncyclizedsorbitol.

In one example, the sorbitan fabric conditioning active agents and/orhair conditioning active agents of the type employed herein can beprepared by esterifying the “sorbitan” mixture with a fatty acyl groupin standard fashion, e.g., by reaction with a fatty acid halide, fattyacid ester, and/or fatty acid. The esterification reaction can occur atany of the available hydroxyl groups, and various mono-, di-, etc.,esters can be prepared. In fact, mixtures of mono-, di-, tri-, etc.,esters almost always result from such reactions, and the stoichiometricratios of the reactants can be simply adjusted to favor the desiredreaction product.

For commercial production of the sorbitan ester materials,etherification and esterification are generally accomplished in the sameprocessing step by reacting sorbitol directly with fatty acids. Such amethod of sorbitan ester preparation is described more fully inMacDonald, “Emulsifiers: Processing and Quality Control”, Journal of theAmerican Oil Chemists' Society, Vol. 45, October 1968. Details,including formula, of the examples of sorbitan esters can be found inU.S. Pat. No. 4,128,484, incorporated hereinbefore by reference.

Certain derivatives of the sorbitan esters herein, especially the“lower” ethoxylates thereof (i.e., mono-, di-, and tri-esters whereinone or more of the unesterified —OH groups contain one to about twentyoxyethylene moieties (Tweens®) are also useful in the articles of thepresent invention. Therefore, the term “sorbitan ester” is intended toinclude such derivatives.

For the purposes of the present invention, in one example, a significantamount of di- and tri-sorbitan esters are present in the ester mixture.In another example, an ester mixture may have from about 20-50%mono-ester, about 25-50% di-ester and about 10-35% of tri- andtetra-esters. Material which is sold commercially as sorbitan mono-ester(e.g., monostearate) typically contains significant amounts of di- andtri-esters. A typical analysis of commercial sorbitan monostearateindicates that it comprises about 27% mono-, about 32% di- and about 30%tri- and tetra-esters. Mixtures of sorbitan stearate and sorbitanpalmitate having stearate/palmitate weight ratios varying between 10:1and 1:10, and 1,5-sorbitan esters are also useful. In addition, both the1,4- and 1,5-sorbitan esters are useful herein.

Other useful alkyl sorbitan esters for use as fabric conditioning activeagents and/or hair conditioning active agents herein include sorbitanmonolaurate, sorbitan monomyristate, sorbitan monopalmitate, sorbitanmonobehenate, sorbitan monooleate, sorbitan dilaurate, sorbitandimyristate, sorbitan dipalmitate, sorbitan distearate, sorbitandibehenate, sorbitan dioleate, and mixtures thereof, and mixedtallowalkyl sorbitan mono- and di-esters. Such mixtures are readilyprepared by reacting the foregoing hydroxy-substituted sorbitans,particularly the 1,4- and 1,5-sorbitans, with the corresponding acid,ester, or acid chloride in a simple esterification reaction. It is to berecognized, of course, that commercial materials prepared in this mannerwill comprise mixtures usually containing minor proportions ofuncyclized sorbitol, fatty acids, polymers, isosorbide structures, andthe like. In the present invention, it is desirable to keep suchimpurities present at as low a level as practical.

The sorbitan esters employed herein may contain up to about 15% byweight of esters of the C₂₀-C₂₆, and higher, fatty acids, as well asminor amounts of C₈, and lower, fatty esters.

Glycerol and polyglycerol esters, especially glycerol, diglycerol,triglycerol, and polyglycerol mono- and/or di-esters, in one examplemono- (e.g., polyglycerol monostearate with a trade name of Radiasurf7248). Glycerol esters can be prepared from naturally occurringtriglycerides by normal extraction, purification and/orinteresterification processes or by esterification processes of the typeset forth hereinbefore for sorbitan esters. Partial esters of glycerincan also be ethoxylated to form usable derivatives that are includedwithin the term “glycerol esters.”

Useful glycerol and polyglycerol esters include mono-esters withstearic, oleic, palmitic, lauric, isostearic, myristic, and/or behenicacids and the diesters of stearic, oleic, palmitic, lauric, isostearic,behenic, and/or myristic acids. It is understood that the typicalmono-ester contains some di- and tri-ester, etc.

The “glycerol esters” also include the polyglycerol, e.g., diglycerolthrough octaglycerol esters. The polyglycerol polyols are formed bycondensing glycerin or epichlorohydrin together to link the glycerolmoieties via ether linkages. The mono- and/or diesters of thepolyglycerol polyols may be used, the fatty acyl groups typically beingthose described hereinbefore for the sorbitan and glycerol esters.

Fatty Fabric Conditioning Active Agents and/or Hair Conditioning ActiveAgents

The fibrous elements and/or films and/or articles of the presentinvention further comprise one or more fatty fabric conditioning activeagents and/or fatty hair conditioning active agents, for example one ormore high melting point fatty compounds. The high melting point fattycompound can be included in the composition at a level of from about 10wt % to about 85 wt % and/or from 20 wt % to 70 wt % and/or from about50 wt % to about 70 wt % and/or from about 10 wt % to about 20 wt % ofthe fibrous element and/or film and/or article. In one example, thefatty fabric conditioning active agent and/or fatty hair conditioningactive agent is selected from the group consisting of: fattyamphiphiles, fatty alcohols, fatty acids, fatty amides, fatty esters andmixtures thereof.

In one example, the fatty fabric conditioning active agents and/or fattyhair conditioning active agents have a melting point of 25° C. or higherand/or 40° C. or higher and/or 45° C. or higher and/or 50° C. or higherand/or to about 90° C. and/or to about 80° C. and/or to about 70° C.and/or to about 65° C. and are considered as high melting point fattyfabric conditioning active agents and/or high melting point fatty hairconditioning active agents. The fatty fabric conditioning active agentand/or fatty hair conditioning active agent may be used as a singlecompound or as a blend or mixture of at least two fatty fabricconditioning active agents and/or a mixture of at least two fatty hairconditioning active agents. When used as such blend or mixture, theabove melting point means the melting point of the blend or mixture.

The fatty fabric conditioning active agents and/or fatty hairconditioning active agents useful herein may be selected from the groupconsisting of fatty alcohols, fatty acids, fatty alcohol derivatives,fatty acid derivatives, and mixtures thereof. It is understood by theartisan that the fatty fabric conditioning active agents and/or fattyhair conditioning active agents disclosed herein may in some instancesfall into more than one classification, e.g., some fatty alcoholderivatives can also be classified as fatty acid derivatives. However, agiven classification is not intended to be a limitation on thatparticular compound, but is done so for convenience of classificationand nomenclature. Further, it is understood by the artisan that,depending on the number and position of double bonds, and length andposition of the branches, certain fatty fabric conditioning activeagents and/or fatty hair conditioning active agents having certainrequired carbon atoms may have a melting point of less than the above.Such fatty fabric conditioning active agents and/or fatty hairconditioning active agents of low melting point (a melting point lessthan 25° C. and/or less than 20° C.) are not intended to be included inthis section. Non-limiting examples of the high melting point fattyfabric conditioning active agents and/or high melting point fatty hairconditioning active agents are found in International CosmeticIngredient Dictionary, Fifth Edition, 1993, and CTFA Cosmetic IngredientHandbook, Second Edition, 1992.

Fatty Acids

The fabric conditioning active agents and/or hair conditioning activeagents in the articles of the present invention may further comprise oneor more fatty acids. Typically, the fatty acid is present to improve theprocessability of the composition, and is admixed with any material, ormaterials, that are difficult to process, especially as a result ofhaving a high viscosity. The fatty acid provides improved viscosityand/or processability, without harming softening or antistaticperformance of the article.

Non-limiting examples of suitable fatty acids are those containing along chain, unsubstituted alkenyl group of from about 8 to about 30carbon atoms and/or from about 11 to about 18 carbon atoms. Examples ofspecific carboxylic acids are: oleic acid, linoleic acid, and mixturesthereof. Although unsaturated fatty acids are desirable, the unsaturatedfatty acids can also be used in combination with saturated fatty acidslike stearic, palmitic, and/or lauric acids. Non-limiting examples ofsuitable carboxylic acids are oleic, linoleic, tallow fatty acids, andmixtures thereof.

In one example, the fatty acid is added to the quaternization reactionmixture used to form the biodegradable quaternary ammonium compounds ofFormulas II, III, and/or IV as described hereinbefore to lower theviscosity of the reaction mixture to less than about 1500 cps and/orless than about 1000 cps and/or less than about 800 cps. The solventlevel of added fatty acid may be from about 5% to about 30% and/or fromabout 10% to about 25% and/or from about 10% to about 20%. Theunsaturated fatty acid can be added before the start of thequaternization reaction and/or may be added during the quaternizationreaction when it is needed to reduce the viscosity which increases withincreased level of quaternization. In one example, the addition occurswhen at least about 60% of the product is quaternized. This allows for alow viscosity for processing while minimizing side reactions that canoccur when the quaternizing agent reacts with the fatty acid. Thequaternization reactions are well known and include, e.g., with respectto Formula IA and/or IB compounds, those processes described in U.S.Pat. No. 3,915,867, Kang et al., issued Oct. 28, 1975; U.S. Pat. No.4,830,771, Ruback et al., issued May 16, 1989; and U.S. Pat. No.5,296,622, Uphues et al., issued Mar. 22, 1994, all of said patentsbeing incorporated herein by reference. The resulting quaternizedbiodegradable fabric conditioning active agents can be used withoutremoval of the unsaturated fatty acid, and, in fact, are more usefulsince the mixture is more fluid and more easily handled.

Another example of a type of fabric conditioning active agents and/orhair conditioning active agents is described in detail in U.S. Pat. No.4,661,269, Toan Trinh, Errol H. Wahl, Donald M. Swartley and Ronald L.Hemingway, issued Apr. 28, 1987, said patent being incorporated hereinby reference

Fatty Alcohols

Non-limiting examples of suitable fatty alcohols useful as fatty fabricconditioning active agents and/or fatty hair conditioning active agentsare those fatty alcohols having from about 14 to about 30 carbon atomsand/or from about 16 to about 22 carbon atoms. These fatty alcohols aresaturated and can be straight or branched chain alcohols.

Suitable fatty alcohols include, but are not limited to, cetyl alcohol(having a melting point of about 56° C.), stearyl alcohol (having amelting point of about 58-59° C.), behenyl alcohol (having a meltingpoint of about 71° C.), and mixtures thereof. These fatty alcohols areknown to have the above referenced melting points, however, they oftenhave lower melting points when supplied, since such supplied productsare often mixtures of fatty alcohols having alkyl chain lengthdistributions in which the main alkyl chain is cetyl, stearyl or behenylgroup. Generally, in the mixture, the weight ratio of cetyl alcohol tostearyl alcohol can be from about 1:9 to 9:1 and/or from about 1:4 toabout 4:1 and/or from about 1:2.3 to about 1.5:1.

Dispersing Agents

In one example, the fabric conditioning active agents and/or hairconditioning active agents may comprise a dispersing agent. Thedispersing agent, when present, greatly increases the wetting,hydration, and dispersion of the fabric conditioning active agentsand/or hair conditioning active agents. The dispersing agent can beincluded at a level of from about 1 wt % to about 30 wt % of thecomposition, alternatively from about 5 wt % to about 15 wt %, andalternatively from about 5 wt % to about 10 wt %. A surfactant from thenonionic class of alkyl glucamides can improve the wetting and hydrationwhen added to the solid conditioner formula. The alkyl glucamidesurfactant contains a hydrophobic tail of about 8-18 carbons and anonionic head group of glucamide. For glucamide, the presence of theamide and hydroxyl groups may provide sufficient polarity that balancesthe hydrophobic carbon tail in such a way to permit the surfactant'ssolubility in the conditioner oils and also imparts a rapid dispersionof the conditioner ingredients upon exposure to water. Other similardispersing agents include, but are not limited to, reverse alkylglucamides, cocoamiodpropyl betaines, alkyl glucoside, Triethanol amine,cocamide MEAs and mixtures thereof.

Cationic Surfactants

The fabric conditioning active agent and/or hair conditioning activeagent of the present invention may comprise a cationic surfactant. Whenpresent, the cationic surfactant may be present at a level of from about1 wt % to about 60 wt %, alternatively from about 10 wt % to about 50 wt%, alternatively from about 20 wt % to about 40 wt % of the article.

Cationic surfactants useful herein can be one cationic surfactant or amixture of two or more cationic surfactants. The cationic surfactant canbe selected from the group consisting of, but not limited to: amono-long alkyl quaternized ammonium salt; a combination of a mono-longalkyl quaternized ammonium salt and a di-long alkyl quaternized ammoniumsalt; a mono-long alkyl amine; a combination of a mono-long alkyl amineand a di-long alkyl quaternized ammonium salt; and a combination of amono-long alkyl amine and a mono-long alkyl quaternized ammonium salt, atertiary amine and combinations thereof.

Mono-Long Alkyl Amines

Mono-long alkyl amine useful herein are those having one long alkylchain of from 12 to 30 carbon atoms, alternatively from 16 to 24 carbonatoms, alternatively from 18 to 22 alkyl group. Mono-long alkyl aminesuseful herein also include mono-long alkyl amidoamines. Primary,secondary, and tertiary fatty amines are useful.

Suitable for use in the articles of the present invention are tertiaryamido amines having an alkyl group of from about 12 to about 22 carbons.Exemplary tertiary amido amines include: stearamidopropyldimethylamine,stearamidopropyldiethylamine, stearamidoethyldiethylamine,stearamidoethyldimethylamine, palmitamidopropyldimethylamine,palmitamidopropyldiethylamine, palmitamidoethyldiethylamine,palmitamidoethyldimethylamine, behenamidopropyldimethylamine,behenamidopropyldiethylamine, behenamidoethyldiethylamine,behenamidoethyldimethylamine, arachidamidopropyldimethylamine,arachidamidopropyldiethylamine, arachidamidoethyldiethylamine,arachidamidoethyldimethylamine, diethylaminoethylstearamide. Usefulamines in the present invention are disclosed in U.S. Pat. No.4,275,055, Nachtigal, et al.

These amines can be used in combination with acids such as l-glutamicacid, lactic acid, hydrochloric acid, malic acid, succinic acid, aceticacid, fumaric acid, tartaric acid, citric acid, l-glutamichydrochloride, maleic acid, and mixtures thereof; alternativelyl-glutamic acid, lactic acid, citric acid, at a molar ratio of the amineto the acid of from about 1:0.3 to about 1:2, alternatively from about1:0.4 to about 1:1.

Mono-Long Alkyl Quaternized Ammonium Salts

The mono-long alkyl quaternized ammonium salts useful herein are thosehaving one long alkyl chain which has from 12 to 30 carbon atoms,alternatively from 16 to 24 carbon atoms, alternatively a C18-22 alkylgroup. The remaining groups attached to nitrogen are independentlyselected from an alkyl group of from 1 to about 4 carbon atoms or analkoxy, polyoxyalkylene, alkylamido, hydroxyalkyl, aryl or alkylarylgroup having up to about 4 carbon atoms.

Mono-long alkyl quaternized ammonium salts useful herein are thosehaving the following formula (V):

wherein one of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ is selected from an alkyl group offrom 12 to 30 carbon atoms or an aromatic, alkoxy, polyoxyalkylene,alkylamido, hydroxyalkyl, aryl or alkylaryl group having up to about 30carbon atoms; the remainder of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ are independentlyselected from an alkyl group of from 1 to about 4 carbon atoms or analkoxy, polyoxyalkylene, alkylamido, hydroxyalkyl, aryl or alkylarylgroup having up to about 4 carbon atoms; and X⁻ is a salt-forming anionsuch as those selected from halogen, (e.g. chloride, bromide), acetate,citrate, lactate, glycolate, phosphate, nitrate, sulfonate, sulfate,alkylsulfate, and alkyl sulfonate radicals. The alkyl groups cancontain, in addition to carbon and hydrogen atoms, ether and/or esterlinkages, and other groups such as amino groups. The longer chain alkylgroups, e.g., those of about 12 carbons, or higher, can be saturated orunsaturated. One of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ can be selected from an alkylgroup of from 12 to 30 carbon atoms, alternatively from 16 to 24 carbonatoms, alternatively from 18 to 22 carbon atoms, alternatively 22 carbonatoms; the remainder of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ can be independentlyselected from CH₃, C₂H₅, C₂H₄OH, and mixtures thereof; and X can beselected from the group consisting of Cl, Br, CH₃OSO₃, C₂H₅OSO₃, andmixtures thereof.

Nonlimiting examples of such mono-long alkyl quaternized ammonium saltcationic surfactants include: behenyl trimethyl ammonium salt; stearyltrimethyl ammonium salt; cetyl trimethyl ammonium salt; and hydrogenatedtallow alkyl trimethyl ammonium salt.

Di-Long Alkyl Quaternized Ammonium Salts

When used, di-long alkyl quaternized ammonium salts can be combined witha mono-long alkyl quaternized ammonium salt and/or mono-long alkyl aminesalt, at the weight ratio of from 1:1 to 1:5, alternatively from 1:1.2to 1:5, alternatively from 1:1.5 to 1:4, in view of stability inrheology and conditioning benefits.

Di-long alkyl quaternized ammonium salts useful herein are those havingtwo long alkyl chains of from 12 to 30 carbon atoms, alternatively from16 to 24 carbon atoms, alternatively from 18 to 22 carbon atoms. Suchdi-long alkyl quaternized ammonium salts useful herein are those havingthe formula (VI):

wherein two of R⁷¹, R⁷², R⁷³ and R⁷⁴ are selected from an aliphaticgroup of from 12 to 30 carbon atoms, alternatively from 16 to 24 carbonatoms, alternatively from 18 to 22 carbon atoms or an aromatic, alkoxy,polyoxyalkylene, alkylamido, hydroxyalkyl, aryl or alkylaryl grouphaving up to about 30 carbon atoms; the remainder of R⁷¹, R⁷², R⁷³ andR⁷⁴ are independently selected from an aliphatic group of from 1 toabout 8 carbon atoms, alternatively from 1 to 3 carbon atoms or anaromatic, alkoxy, polyoxyalkylene, alkylamido, hydroxyalkyl, aryl oralkylaryl group having up to about 8 carbon atoms; and X⁻ is asalt-forming anion selected from the group consisting of halides such aschloride and bromide, C1-C4 alkyl sulfate such as methosulfate andethosulfate, and mixtures thereof. The aliphatic groups can contain, inaddition to carbon and hydrogen atoms, ether linkages, and other groupssuch as amino groups. The longer chain aliphatic groups, e.g., those ofabout 16 carbons, or higher, can be saturated or unsaturated. Two ofR⁷¹, R⁷², R⁷³ and R⁷⁴ can be selected from an alkyl group of from 12 to30 carbon atoms, alternatively from 16 to 24 carbon atoms, alternativelyfrom 18 to 22 carbon atoms; and the remainder of R⁷¹, R⁷², R⁷³ and R⁷⁴are independently selected from CH₃, C₂H₅, C₂H₄OH, CH₂C₆H₅, and mixturesthereof.

Suitable di-long alkyl cationic surfactants include, for example,dialkyl (14-18) dimethyl ammonium chloride, ditallow alkyl dimethylammonium chloride, dihydrogenated tallow alkyl dimethyl ammoniumchloride, distearyl dimethyl ammonium chloride, and dicetyl dimethylammonium chloride.

Optional Ingredients

In addition to the one or more fabric conditioning active agents and/orhair conditioning active agents described above, the articles of thepresent invention may further comprise one or more optional ingredients.When present, the one or more optional ingredients may be present inand/or on the article at a level of from about 0.01% to about 10% and/orfrom about 0.1% to about 5% and/or from about 0.1% to about 2% by weightof the article. Non-limiting examples of such optional ingredientinclude soil release agents, such as soil release polymers, for examplesoil release polymer that comprise copolymeric blocks of terephthalateand polyethylene oxide or polypropylene oxide, and cationic soil releaseagents, anti-oxidants, colorants, preservatives, optical brighteners,opacifiers, stabilizers such as guar gum and polyethylene glycol,anti-shrinkage agents, anti-wrinkle agents, soil release agents, fabriccrisping agents, reductive agents, spotting agents, germicides,fungicides, anti-corrosion agents, antifoam agents, deterrent agents,such as bittering agents, and the like.

Non-limiting examples of suitable deterrent agents are found in U.S.Patent Application Publication No. US 2016-0258083 A1.

Auxiliary Ingredients

In addition to the one or more active agents, the articles of thepresent invention may further comprise one or more auxiliaryingredients, for example one or more structurants.

Non-limiting examples of suitable auxiliary ingredients, for examplestructurants, are selected from the group consisting of: polymericstructurants, inorganic structurants, and mixtures thereof. In oneexample, the auxiliary ingredient, for example structurant, comprises apolymeric structurant selected from the group consisting of:polyvinylpyrrolidone, copolymers of vinylpyrrolidone,polydimethylacrylamide, copolymers of dimethylacrylamide, and mixturesthereof. In one example, the structurant comprises polyvinylpyrrolidone.In one example, the structurant comprises polydimethylacrylamide. In oneexample, the structurant comprises an inorganic structurant selectedfrom the group consisting of clays, silica, and mixtures thereof.

The one or more auxiliary ingredients, for example one or morestructurants, when present, may be dispersed throughout, for examplehomogeneously, the one or more active agents within the filament-formingcomposition and/or fibrous element and/or fibrous structure and/or filmstructure and/or article.

When present, the one or more auxiliary ingredients may be present inthe filament-forming composition and/or fibrous element and/or fibrousstructure and/or film structure and/or article at a total level of lessthan 20% or less and/or less than 15% and/or less than 10% and/or lessthan 5% and/or less than 4% and/or less than 3% and/or less than 2%and/or less than 1% and/or about 0% by weight on a dry filament-formingcomposition and/or a dry fibrous element and/or dry film structureand/or dry fibrous structure and/or dry article basis.

Method for Making Filament-Forming Composition

The filament-forming composition of the present invention may be made byany suitable process so long as the filament-forming composition issuitable for making the article of the present invention.

In one example, one or more active agents, for example one or morefabric conditioning active agents and/or hair conditioning activeagents, are added (in the absence of free water) to a metal beaker andheated to a temperature sufficient to melt the active agents, forexample 80° C. The active agents are melted and optionally agitateduntil they form a homogeneous fluid.

After melting the active agents, one or more auxiliary ingredients, forexample one or more filament-forming materials, such as one or morestructurants, may be added to the homogeneous fluid of active agents.The auxiliary ingredients, when added, are stirred into the homogeneousfluid of active agents until the auxiliary ingredients are dispersed,for example homogeneously dispersed, throughout the homogeneous fluid ofactive agents and/or are homogeneously dissolved within the homogeneousfluid of active agents. This all occurs while maintaining thehomogeneous fluid of active agents at a temperature of at least themelting point of the lowest melting point active agent, for example 80°C.

The filament-forming composition may then be used to make fibrouselements and/or fibrous structures and/or film structures and/orarticles of the present invention.

Method for Making Fibrous Elements

The fibrous elements of the present invention may be made by anysuitable process. A non-limiting example of a suitable process formaking the fibrous elements is described below.

As shown in FIGS. 14 and 15, the fibrous elements of the presentinvention may be made as follows. Fibrous elements may be formed bymeans of a small-scale apparatus, a schematic representation of which isshown in FIGS. 14 and 15. A pressurized tank 39, suitable for batchoperation is filled with a suitable filament-forming compositionaccording to the present invention. A pump 40 such as a Zenith®, typePEP II, having a capacity of 5.0 cubic centimeters per revolution(cm³/rev), manufactured by Parker Hannifin Corporation, Zenith Pumpsdivision, of Sanford, N.C., USA may be used to facilitate transport ofthe filament-forming composition via pipes 41 to a spinning die 42. Theflow of the filament-forming composition from the pressurized tank 39 tothe spinning die 42 may be controlled by adjusting the number ofrevolutions per minute (rpm) of the pump 40. Pipes 41 are used toconnect the pressurized tank 39, the pump 40, and the spinning die 42.

The spinning die 42 shown in FIG. 14 has several rows of circularextrusion nozzles (fibrous element-forming holes 44) spaced from oneanother at a pitch P of about 1.524 millimeters (about 0.060 inches).The nozzles have individual inner diameters of about 0.305 millimeters(about 0.012 inches) and individual outside diameters of about 0.813millimeters (about 0.032 inches). Each individual nozzle is encircled byan annular and divergently flared orifice (concentric attenuation fluidhole 48 to supply attenuation air to each individual melt capillary 46.The filament-forming composition extruded through the nozzles issurrounded and attenuated by generally cylindrical, humidified airstreams supplied through the orifices.

In one example, as shown in FIGS. 14 and 15, a method for making afibrous element 10 according to the present invention comprises thesteps of:

a. providing a filament-forming composition comprising one or morefilament-forming materials, and optionally one or more active agents;and

b. spinning the filament-forming composition, such as via a spinning die42, into one or more fibrous elements, such as filaments 10, comprisingthe one or more filament-forming materials and optionally, the one ormore active agents. The one or more active agents may be releasable fromthe fibrous element when exposed to conditions of intended use. Thetotal level of the one or more filament-forming materials present in thefibrous element, for example filament 10, when active agents are presenttherein, may be less than 80% and/or less than 70% and/or less than 65%and/or 50% or less by weight on a dry fibrous element basis and/or dryfibrous structure basis and the total level of the one or more activeagents, when present in the fibrous element may be greater than 20%and/or greater than 35% and/or 50% or greater 65% or greater and/or 80%or greater by weight on a dry fibrous element basis and/or dry fibrousstructure basis.

As shown in FIG. 15, the spinning die 42 may comprise a plurality offibrous element-forming holes 44 that include a melt capillary 46encircled by a concentric attenuation fluid hole 48 through which afluid, such as air, passes to facilitate attenuation of thefilament-forming composition into a fibrous element, for example afilament 10 as it exits the fibrous element-forming hole 44.

Attenuation air can be provided by heating compressed air from a sourceby an electrical-resistance heater, for example, a heater manufacturedby Chromalox, Division of Emerson Electric, of Pittsburgh, Pa., USA. Anappropriate quantity of steam was added to saturate or nearly saturatethe heated air at the conditions in the electrically heated,thermostatically controlled delivery pipe. Condensate is removed in anelectrically heated, thermostatically controlled, separator.

The embryonic fibrous elements are dried by a drying air stream having atemperature from about 149° C. (about 300° F.) to about 315° C. (about600° F.) by an electrical resistance heater (not shown) supplied throughdrying nozzles and discharged at an angle of about 90° relative to thegeneral orientation of the embryonic fibrous elements being extruded.The dried embryonic fibrous elements are collected on a collectiondevice, such as, for example, a movable foraminous belt or patternedcollection belt. The addition of a vacuum source directly under theformation zone may be used to aid collection of the fibers.

In one example, during the spinning step, any volatile solvent, such aswater, present in the filament-forming composition is removed, such asby drying, as the fibrous element 10 is formed. In one example, greaterthan 30% and/or greater than 40% and/or greater than 50% of the weightof the filament-forming composition's volatile solvent, such as water,is removed during the spinning step, such as by drying the fibrouselement being produced.

The filament-forming composition may comprise any suitable total levelof filament-forming materials and any suitable level of active agents solong as the fibrous element produced from the filament-formingcomposition comprises a total level of filament-forming materials in thefibrous element of from about 5% to 50% or less by weight on a dryfibrous element basis and/or dry particle basis and/or dry fibrousstructure basis and a total level of active agents in the fibrouselement of from 50% to about 95% by weight on a dry fibrous elementbasis and/or dry particle basis and/or dry fibrous structure basis.

In one example, the filament-forming composition may comprise anysuitable total level of filament-forming materials and any suitablelevel of active agents so long as the fibrous element produced from thefilament-forming composition comprises a total level of filament-formingmaterials in the fibrous element and/or particle of from about 5% to 50%or less by weight on a dry fibrous element basis and/or dry particlebasis and/or dry fibrous structure basis and a total level of activeagents in the fibrous element and/or particle of from 50% to about 95%by weight on a dry fibrous element basis and/or dry particle basisand/or dry fibrous structure basis, wherein the weight ratio offilament-forming material to total level of active agents is 1 or less.

In one example, the filament-forming composition comprises from about 1%and/or from about 5% and/or from about 10% to about 50% and/or to about40% and/or to about 30% and/or to about 20% by weight of thefilament-forming composition of filament-forming materials; from about1% and/or from about 5% and/or from about 10% to about 50% and/or toabout 40% and/or to about 30% and/or to about 20% by weight of thefilament-forming composition of active agents; and from about 20% and/orfrom about 25% and/or from about 30% and/or from about 40% and/or toabout 80% and/or to about 70% and/or to about 60% and/or to about 50% byweight of the filament-forming composition of a volatile solvent, suchas water. The filament-forming composition may comprise minor amounts ofother active agents, such as less than 10% and/or less than 5% and/orless than 3% and/or less than 1% by weight of the filament-formingcomposition of plasticizers, pH adjusting agents, and other activeagents.

The filament-forming composition is spun into one or more fibrouselements and/or particles by any suitable spinning process, such asmeltblowing, spunbonding, electro-spinning, and/or rotary spinning. Inone example, the filament-forming composition is spun into a pluralityof fibrous elements and/or particles by meltblowing. For example, thefilament-forming composition may be pumped from a tank to a meltblownspinnerette. Upon exiting one or more of the filament-forming holes inthe spinnerette, the filament-forming composition is attenuated with airto create one or more fibrous elements and/or particles. The fibrouselements and/or particles may then be dried to remove any remainingsolvent used for spinning, such as the water.

The fibrous elements and/or particles of the present invention may becollected on a belt, such as a patterned belt to form a fibrousstructure comprising the fibrous elements and/or particles.

Method for Making Article

In one example, the filament-forming composition of the presentinvention may be made by the following steps:

-   -   a. subjecting one or more active agents to a temperature        sufficient to melt the active agents, such as greater than        70° C. and/or from about 75° C. to about 100° C. and/or from        about 80° C. (in the absence of water) to form a        filament-forming composition;    -   b. producing one or more fibrous elements and/or films from the        filament-forming composition to form an article according to the        present invention.

In one example, the fibrous elements and/or films of the presentinvention may be made by any suitable processes. A non-limiting exampleof a suitable process for making the fibrous elements is describedbelow.

As shown in FIG. 16, a fibrous structure, for example a fibrousstructure layer or ply 22 of the present invention may be made byspinning a filament-forming composition from a spinning die 42, asdescribed in FIGS. 14 and 15, to form a plurality of fibrous elements,such as filaments 10, and then optionally, associating one or moreparticles 26 provided by a particle source 50, for example a sifter or aairlaid forming head. The particles 26 may be dispersed within thefibrous elements, for example filaments 10. The mixture of particles 26and fibrous elements, for example filaments 10 may be collected on acollection belt 52, such as a patterned collection belt that imparts atexture, such as a three-dimensional texture to at least one surface ofthe fibrous structure layer or ply 22.

FIG. 17 illustrates an example of a method for making an article 20according to FIG. 5. The method comprises the steps of forming a firstfibrous structure layer 22 of a plurality of fibrous elements, forexample filaments 10 such that pockets 28 are formed in a surface of thefirst fibrous structure layer 22. One or more particles 26 are depositedinto the pockets 28 from a particle source 50. A second fibrousstructure layer 24 comprising a plurality of fibrous elements, forexample filaments 10 produced from a spinning die 42 are then formed onthe surface of the first fibrous structure layer 22 such that theparticles 26 are entrapped in the pockets 28.

FIG. 18 illustrates yet another example of a method for making anarticle 20 according to FIG. 4. The method comprises the steps offorming a first fibrous structure layer 22 of a plurality of fibrouselements, for example filaments 10. One or more particles 26 aredeposited onto a surface of the first fibrous structure layer 22 from aparticle source 50. A second fibrous structure layer 24 comprising aplurality of fibrous elements, for example filaments 10 produced from aspinning die 42 are then formed on top of the particles 26 such that theparticles 26 are positioned between the first fibrous structure layer 22and the second fibrous structure layer 24.

The dry embryonic fibrous elements, for example filaments may becollected on a molding member as described above. The construction ofthe molding member may provide areas that are air-permeable due to theinherent construction. The filaments that are used to construct themolding member will be non-permeable while the void areas between thefilaments will be permeable. Additionally, a pattern may be applied tothe molding member to provide additional non-permeable areas which maybe continuous, discontinuous, or semi-continuous in nature. A vacuumused at the point of lay down is used to help deflect fibers into thepresented pattern. An example of one of these molding members is shownin FIG. 19.

In addition to the techniques described herein in forming regions withinthe fibrous structures having different properties (e.g., averagedensities), other techniques can also be applied to provide suitableresults. One such example includes embossing techniques to form suchregions. Suitable embossing techniques are described in U.S. PatentApplication Publication Nos. 2010/0297377, 2010/0295213, 2010/0295206,2010/0028621, and 2006/0278355.

In one example, in a multi-ply article, one or more fibrous structureplies may be formed and/or deposited directly upon an existing ply offibrous structure to form a multi-ply fibrous structure. The two or moreexisting fibrous structure plies may be combined, for example viathermal bonding, gluing, embossing, aperturing, rodding, rotary knifeaperturing, die cutting, die punching, needlepunching, knurling,pneumatic forming, hydraulic forming, laser cutting, tufting, and/orother mechanical combining process, with one or more other existingfibrous structure plies to form the multi-ply article of the presentinvention.

Package

The articles of the present invention may be enclosed in a package,individually wrapped and/or multi-article wrapped. In one example, thepackage exhibits a moisture barrier with a water vapor transmission rateof less than about 1.0 g H₂O/day/m² and/or less than about 0.5 gH₂O/day/m² and/or less than about 0.3 g H₂O/day/m² and/or about 0.1 gH₂O/day/m².

Method of Use

The present invention also provides for a method of using the articlesof the present invention to treat fabrics, for example to provide fabricconditioning benefits to fabrics during a drying process, for example anautomatic clothes dryer drying process and/or in a washing machineoperation and/or to treat hair, for example to provide hair conditioningbenefits to hair during a treating process. In one example, a method oftreating fabrics in an automatic clothes dryer drying process comprisesthe step of contacting a fabric with an article according to the presentinvention within the dryer tub of an automatic clothes drying machinesuch that the fabric is treated. The step of contacting comprises thestep of transferring (depositing) at least a portion of the article'smass to the fabric, for example such that the mass of articletransferred to (deposited on) the fabric does not result in a stain onthe fabric. It is believed that the fabric conditioning active agentsare released from the article of the present invention, due in part tothe tumbling action and/or the heated air of the automatic clothesdryer.

In one example, the article of the present invention is suitable for asingle use, in other words, the article is a consumable, single-usearticle, since it is designed to disappear in the automatic clothesdryer drying process. In other words, the article, which is dry, forexample dry-to-the-touch, is a dryer-added article that disappearsand/or is entirely consumed and/or is entirely transferred to (depositedon) fabrics during use in the automatic clothes dryer drying process.“Dry-to-the-touch” as used herein means an article is substantially freeof liquids, for example water, such that it does not feel damp or wetprior to being subjected to water or other liquids. In other words, adry-to-the-touch article of the present invention does not containliquids, such as water. In one non-limiting example, a dry-to-the-toucharticle has a water content of less than about 20% and/or less thanabout 15% and/or less than about 10% and/or less than about 5% and/orless than about 3% and/or less than about 1% and/or about 0% as measuredaccording to the Water Content Test Method described herein.

In one example, the articles of the present invention may be used forimparting the fabric conditioning active agents to fabrics to providefabric conditioning benefits such as softening, anti-static effects, andimproved perfume deposition on the fabrics in an automatic clothesdryer. Generally, the method of using the articles of the presentinvention comprises: commingling pieces of damp and/or dry fabric bytumbling the fabrics under heat in an automatic clothes dryer with oneor more articles of the present invention. In one example, the articlesof the present invention exhibit a viscosity of less than about 2000 cpsat 38° C. and a melting point greater than about 25° C. and/or fromabout 35° C. to about 100° C. such that the article is flowable atautomatic clothes dryer operating temperatures.

In one example, a method of treating fabrics in a washing machineprocess comprises the step of contacting a fabric with an articleaccording to the present invention within the washing machine tub suchthat the fabric is treated. The step of contacting comprises the step oftransferring (depositing) at least a portion of the article's mass tothe fabric, for example such that the mass of article transferred to(deposited on) the fabric does not result in a stain or visible residueon the fabric. It is believed that the fabric conditioning active agentsare released from the article, due in part to the tumbling action and/orthe water and/or heated air and/or water of the washing machine.

In one example, the article of the present invention is suitable for asingle use, in other words, the article is a consumable, single-usearticle, since it is designed to disappear in the washing process, forexample washing machine process. In other words, the article, which isdry, for example dry-to-the-touch, is a dryer-added article thatdisappears and/or is entirely consumed and/or is entirely transferred to(deposited on) fabrics during use in the washing process, for examplewashing machine process. In one example, a consumable, single use,dry-to-the-touch dryer-added article, for example wherein theconsumable, single use, dry-to-the-touch dryer added article maycomprise an article, product, and/or multi-article sheet according toany of the present invention is provided. In another example, aconsumable, single use, water-insoluble washing machine-added article,for example wherein the consumable, single use, dry-to-the-touch dryeradded article may comprise an article, product, and/or multi-articlesheet according to the present invention, for example wherein thearticle is a dry-to-the-touch article, is provided. In another example,a consumable, single use, water-insoluble hair care article, for examplewherein the consumable, single use, water-insoluble hair care articlemay comprise an article, product, and/or multi-article sheet accordingto the present invention, for example wherein the article is adry-to-the-touch article.

While not wishing to be bound by theory, the inventors have surprisinglyfound the articles of the present invention provide consumers with aconsumable, single-use article delivering a combination of 1)disappearing and/or being entirely consumed and/or is entirelytransferred to (deposited on) fabrics or other treated surfaces, 2)being dry-to-the-touch, and 3) leaving behind no visible residue on thetreated surface. The inventors have also discovered articles of thepresent invention may also be designed so as they are shippable inefficient e-commerce friendly configurations.

In one example, the articles of the present invention may be used forimparting the fabric conditioning active agents to fabrics to providefabric conditioning benefits such as softening, anti-static effects, andimproved perfume deposition on the fabrics in a washing machine.Generally, the method of using the articles of the present inventioncomprises: commingling pieces of damp and/or wet fabrics by agitatingand/or spinning and/or tumbling the fabrics in the presence of a washliquor, for example water and optionally detergent, and optionally inthe presence of heat in a washing machine with one or more articles ofthe present invention. In one example, the articles of the presentinvention exhibit a viscosity of less than about 2000 cps at 38° C. anda melting point greater than about 25° C. and/or from about 35° C. toabout 100° C. such that the article is flowable under washing machineoperating conditions and/or exhibits a lamellar structure (exhibits alamellar structure response) as measured according to the LamellarStructure Test Method.

In still another example, the articles of the present invention may bemassaged and/or kneaded into one's hair during a shampooing and/orconditioning operation for treating one's hair. In one example, thearticles of the present invention exhibit a viscosity of less than about2000 cps at 38° C. and a melting point greater than about 25° C. and/orfrom about 35° C. to about 100° C. such that the article is flowableunder hair shampooing and/or hair conditioning operating conditionsand/or exhibits a lamellar structure (exhibits a lamellar structureresponse) as measured according to the Lamellar Structure Test Method.

Non-Limiting Examples

Non-limiting examples of articles made from the filament-formingcompositions of the present invention as shown in Table 1 below are madeas follows:

-   -   a. adding one or more active agents to a metal beaker;    -   b. heating the metal beaker to 80° C. with stirring/agitation        until a homogeneous fluid of active agents is formed;    -   c. maintaining the metal beaker at 80° C.; and    -   d. adding an auxiliary ingredient (filament-forming material,        such as a structurant) to the homogeneous fluid of active agents        with stirring/agitation until the auxiliary ingredient is        homogeneously dispersed and/or homogeneously dissolved within        the homogeneous fluid of active agents resulting in a        filament-forming composition that is ready for spinning into        fibrous elements to form a fibrous structure and ultimately an        article; and    -   e. optionally adding optional ingredients, such as perfumes, for        example perfume microcapsules, tackifiers, such as        microcrystalline waxes to facilitate attaching the article to        the interior dryer drum, and other optional ingredients.

In one example, the is suitable for attaching to an internal surface ofan automatic clothes dryer, for example wherein the article comprises anadhesive on at least one surface.

TABLE 1 Fabric Conditioning Active Agents Auxiliary QuaternaryIngredients Ammonium Filament- Compound forming material Filament- A -Di(tallow (Structurant) Forming oxyethyl) Fatty Fabric A - PolyvinylComposition/ hydroxyethylmethyl Conditioning Active Optional pyrrolidoneFibrous ammoniummethylsulfate Agents Nonionic Ingredients PVP K90 ORElement and/or OR B - behenyl Cetyl surfactant Tackifier B - PolyvinylFilm and/or trimonium Stearic Alcohol/Stearyl Alkyl Microcrystallinepyrrolidone Article methosulfate acid Alcohol glucamide wax w835 PVPK120 Example 1 67% by wt A 30% by wt — — — 3% by wt A Example 2 98% bywt A — — — 2% by wt A Example 3 50% by wt A 45% by wt — — — 5% by wt AExample 4 70% by wt A  6% by wt — — 20% by wt 4% by wt A Example 5 66%by wt A 32% by wt/ — — 2% by wt A 0% by wt Example 6 63% by wt A 32% bywt — — — 5% by wt B Example 7 25% by wt B — 18% by wt/ 9% by wt — 4% bywt B 44% by wt

Tables 2 and 3 below show the properties of the articles of Examples 6and 7. In addition, Table 3 also shows some of the properties of acontrol article; namely, a commercially available in 2017 Bounce® dryersheet.

TABLE 2 Filament- Forming Composition/ Fibrous Element and/or FilmArticle Article Article Air and/or Article Width Length HeightPermeability Example 6 10.00 cm 10.00 cm 0.94 mm 1400 L/m²/s Example 710.00 cm 10.00 cm 1.73 mm  452 L/m²/s

TABLE 3 Dry Wet Filament- Lamellar Lamellar Forming Structure asStructure as Composition/ measured measured Fibrous according toaccording to Element and/or Lamellar Lamellar Film and/or ArticleArticle Article Article Free Structure Structure Article Volume MassDensity Melt Flow Test Method Test Method Example 6  9.40 cm³ 1.30 g0.14 g/cm³ 99% — — Example 7 17.30 cm³ 3.10 g 0.18 g/cm³ 75% No YesBounce ® Dryer — 1.79 g — 0.56%  — — SheetTest Methods

Unless otherwise specified, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 23° C.±1.0° C. and a relative humidity of50%±2% for a minimum of 2 hours prior to the test. The samples testedare “usable units.” “Usable units” as used herein means sheets, flatsfrom roll stock, pre-converted flats, and/or single or multi-plyproducts. All tests are conducted under the same environmentalconditions and in such conditioned room. Do not test samples that havedefects such as wrinkles, tears, holes, and like. Samples conditioned asdescribed herein are considered dry samples (such as “dry filaments”)for testing purposes. All instruments are calibrated according tomanufacturer's specifications.

Width and Length Test Method

The length and width of articles having a regular shape (e.g. square,rectangle, circle, oval, etc.) are measured according to theirconventional definitions. For articles of irregular shape, the articlelength may be defined as the maximum feret or caliper diameter, which isthe longest distance between two parallel planes tangential to theboundary of the article. The article width of an irregularly shapedarticle may be defined as the minimum feret or caliper diameter, whichis the shortest distance between two parallel planes tangential to theboundary of the article. The article length and width may be measured byany appropriate instrument that is calibrated, NIST traceable, andcapable of measurements to the nearest 0.01 cm. Measure and record thelength and width of ten (10) substantially similar replicate articles.Average together the 10 individual article length measurements andreport the value to the nearest 0.01 cm. Average together the 10individual article width measurements and report the value to thenearest 0.01 cm.

Height Test Method

The height of an article is measured using a ProGage Thickness Tester(Thwing-Albert Instrument Company, West Berlin, N.J.) with a circularpressure foot diameter of 2.00 inches (area of 3.14 in²) at a pressureof 15.5 g/cm². Ten (10) samples are prepared by cutting samples of aplanar article such that each cut sample is larger in size than thepressure foot surface, avoiding creases, folds, and obvious defects. Ifan article has a length or width less than the diameter of the pressurefoot a smaller diameter pressure foot may be used, while making theappropriate adjustments so that a pressure of 15.5 g/cm² is stillapplied. An individual sample is placed on the anvil with the samplecentered underneath the pressure foot, or centered on the location ofthe maximum height of an article. The foot is lowered at 0.03 in/sec toan applied pressure of 15.5 g/cm². The reading is taken after a 3 seconddwell time, and the foot is raised. The measure is repeated in likefashion for the remaining 9 samples. The thickness or article height iscalculated as the average thickness of the ten samples and is reportedto the nearest 0.01 mm.

Volume Test Method

The volume of an article is calculated by measuring the projected areaof the article, as viewed orthogonally to the plane of the articlelength and width, in square centimeters, as measured according to theWidth and Length Test Method described herein, and then multiplying itby the height of the article in centimeters as measured by the HeightTest Method described herein. Measure and record the volume often (10)substantially similar replicate articles. Average together the 10individual article volume measurements and report the value to thenearest 0.01 cubic centimeters (cm³).

Mass Test Method

The mass of an article is measured using a top loading analyticalbalance with a resolution of ±0.01 g, and is protected from air draftsand other disturbances using a draft shield. Prior to taking the massmeasurement, properly condition the article as previously described.After conditioning, measure the mass of the article to the nearest 0.01g. Measure and record the mass of ten (10) substantially similarreplicate articles. Average together the 10 individual article massmeasurements and report the value to the nearest 0.01 g.

Density Test Method

The density of an article (“article density”) is calculated by dividingthe article mass by the article volume. The article density is reportedto the nearest 0.01 g/cm³.

Basis Weight Test Method

The basis weight of an article is calculated by dividing the articlemass by the projected area of the article as viewed orthogonally to theplane of the article length and width. The article basis weight isreported to the nearest 0.01 g/m².

Tensile Test Method: Elongation, Tensile Strength, TEA and Modulus

Elongation, Tensile Strength, TEA and Tangent Modulus are measured on aconstant rate of extension tensile tester with computer interface (asuitable instrument is the EJA Vantage from the Thwing-Albert InstrumentCo. Wet Berlin, N.J.) using a load cell for which the forces measuredare within 10% to 90% of the limit of the cell. Both the movable (upper)and stationary (lower) pneumatic jaws are fitted with smooth stainlesssteel faced grips, 25.4 mm in height and wider than the width of thetest specimen. An air pressure of about 60 psi is supplied to the jaws.

Eight usable units of a fibrous structure, or article sheet are dividedinto two stacks of four samples each. The samples in each stack areconsistently oriented with respect to machine direction (MD) and crossdirection (CD). One of the stacks is designated for testing in the MDand the other for CD. Using a one inch precision cutter (Thwing AlbertJDC-1-10, or similar) cut 4 MD strips from one stack, and 4 CD stripsfrom the other, with dimensions of 1.00 in +0.01 in wide by 3.0-4.0 inlong. Each strip of one usable unit thick will be treated as a unitaryspecimen for testing.

Program the tensile tester to perform an extension test, collectingforce and extension data at an acquisition rate of 20 Hz as thecrosshead raises at a rate of 2.00 in/min (5.08 cm/min) until thespecimen breaks. The break sensitivity is set to 80%, i.e., the test isterminated when the measured force drops to 20% of the maximum peakforce, after which the crosshead is returned to its original position.

Set the gauge length to 1.00 inch. Zero the crosshead and load cell.Insert at least 1.0 in of the unitary specimen into the upper grip,aligning it vertically within the upper and lower jaws and close theupper grips. Insert the unitary specimen into the lower grips and close.The unitary specimen should be under enough tension to eliminate anyslack, but less than 5.0 g of force on the load cell. Start the tensiletester and data collection. Repeat testing in like fashion for all fourCD and four MD unitary specimens. Program the software to calculate thefollowing from the constructed force (g) verses extension (in) curve:

Tensile Strength is the maximum peak force (g) divided by the samplewidth (in) and reported as g/in to the nearest 1 g/in.

Adjusted Gauge Length is calculated as the extension measured at 3.0 gof force (in) added to the original gauge length (in).

Elongation is calculated as the extension at maximum peak force (in)divided by the Adjusted Gauge Length (in) multiplied by 100 and reportedas % to the nearest 0.1%

Total Energy (TEA) is calculated as the area under the force curveintegrated from zero extension to the extension at the maximum peakforce (g*in), divided by the product of the adjusted Gauge Length (in)and specimen width (in) and is reported out to the nearest 1 g*in/in².

Replot the force (g) verses extension (in) curve as a force (g) versesstrain curve. Strain is herein defined as the extension (in) divided bythe Adjusted Gauge Length (in).

Program the software to calculate the following from the constructedforce (g) verses strain curve:

Tangent Modulus is calculated as the slope of the linear line drawnbetween the two data points on the force (g) versus strain curve, whereone of the data points used is the first data point recorded after 28 gforce, and the other data point used is the first data point recordedafter 48 g force. This slope is then divided by the specimen width (2.54cm) and reported to the nearest 1 g/cm.

The Tensile Strength (g/in), Elongation (%), Total Energy (g*in/in²) andTangent Modulus (g/cm) are calculated for the four CD unitary specimensand the four MD unitary specimens. Calculate an average for eachparameter separately for the CD and MD specimens.

Calculations:Geometric Mean Tensile=Square Root of [MD Tensile Strength (g/in)×CDTensile Strength (g/in)]Geometric Mean Peak Elongation=Square Root of [MD Elongation (%)×CDElongation (%)]Geometric Mean TEA=Square Root of [MD TEA (g*in/in²)×CD TEA (g/in²)]Geometric Mean Modulus=Square Root of [MD Modulus (g/cm)×CD Modulus(g/cm)]Total Dry Tensile Strength (TDT)=MD Tensile Strength (g/in)+CD TensileStrength (g/in)Total TEA=MD TEA (g*in/in²)+CD TEA (g*in/in²)Total Modulus=MD Modulus (g/cm)+CD Modulus (g/cm)Tensile Ratio=MD Tensile Strength (g/in)/CD Tensile Strength (g/in)Water Content Test Method

The water (moisture) content present in an article is measured using thefollowing Water Content Test Method. An article sample, or portionthereof, is placed in a conditioned room at a temperature of 23° C.±1.0C.° and a relative humidity of 50%±2% for at least 24 hours prior totesting. Under the temperature and humidity conditions mentioned above,using a balance with at least four decimal places, the weight of thesample is recorded every five minutes until a change of less than 0.5%of previous weight is detected during a 10 minute period. The finalweight is recorded as the “equilibrium weight”. Within 10 minutes, thesamples are placed into a forced air oven on top of foil, or inside analuminum tray for 24 hours at 70° C.±2 C° at a relative humidity of4%±2% for drying. After the 24 hours of drying, the sample is removedand weighed within 15 seconds. This weight is designated as the “dryweight” of the sample. The water (moisture) content of the sample iscalculated according to the following equation:

${\%\mspace{14mu}{Water}\mspace{14mu}{Content}} = {\frac{{{Equilibrium}\mspace{14mu}{Weight}} - {{Dry}\mspace{14mu}{Weight}}}{{Dry}\mspace{14mu}{Weight}} \times 100}$The % Water Content is measured for 3 replicate samples, and averaged togive the reported to the nearest 0.1%.Median Particle Size Test Method

This test method must be used to determine median particle size.

The median particle size test is conducted to determine the medianparticle size of the seed material using ASTM D 502-89, “Standard TestMethod for Particle Size of Soaps and Other Detergents”, approved May26, 1989, with a further specification for sieve sizes used in theanalysis. Following section 7, “Procedure using machine-sieving method,”a nest of clean dry sieves containing U.S. Standard (ASTM E 11) sieves#8 (2360 um), #12 (1700 um), #16 (1180 um), #20 (850 um), #30 (600 um),#40 (425 um), #50 (300 um), #70 (212 um), #100 (150 um) is required. Theprescribed Machine-Sieving Method is used with the above sieve nest. Theseed material is used as the sample. A suitable sieve-shaking machinecan be obtained from W. S. Tyler Company of Mentor, Ohio, U.S.A.

The data are plotted on a semi-log plot with the micron size opening ofeach sieve plotted against the logarithmic abscissa and the cumulativemass percent (Q₃) plotted against the linear ordinate. An example of theabove data representation is given in ISO 9276-1:1998, “Representationof results of particle size analysis—Part 1: Graphical Representation”,FIG. A.4. The seed material median particle size (D₅₀), for the purposeof the present disclosure, is defined as the abscissa value at the pointwhere the cumulative mass percent is equal to 50 percent, and iscalculated by a straight line interpolation between the data pointsdirectly above (a50) and below (b50) the 50% value using the followingequation:D ₅₀=10{circumflex over ( )}[Log(D _(a50))−(Log(D _(a50))−Log(D_(b50)))*(Q _(a50)−50%)/(Q _(a50) −Q _(b50))]where Q_(a50) and Q_(b50) are the cumulative mass percentile values ofthe data immediately above and below the 50^(th) percentile,respectively; and D_(a50) and D_(b50) are the micron sieve size valuescorresponding to these data.

In the event that the 50^(th) percentile value falls below the finestsieve size (150 um) or above the coarsest sieve size (2360 um), thenadditional sieves must be added to the nest following a geometricprogression of not greater than 1.5, until the median falls between twomeasured sieve sizes.

The Distribution Span of the Seed Material is a measure of the breadthof the seed size distribution about the median. It is calculatedaccording to the following:Span=(D ₈₄ /D ₅₀ +D ₅₀ /D ₁₆)/2

-   -   Where D₅₀ is the median particle size and D₈₄ and D₁₆ are the        particle sizes at the sixteenth and eighty-fourth percentiles on        the cumulative mass percent retained plot, respectively.

In the event that the D₁₆ value falls below the finest sieve size (150um), then the span is calculated according to the following:Span=(D ₈₄ /D ₅₀).

In the event that the D₈₄ value falls above the coarsest sieve size(2360 um), then the span is calculated according to the following:Span=(D ₅₀ /D ₁₆).

In the event that the D₁₆ value falls below the finest sieve size (150um) and the D₈₄ value falls above the coarsest sieve size (2360 um),then the distribution span is taken to be a maximum value of 5.7.

Diameter Test Method

The diameter of a discrete fibrous element or a fibrous element within afibrous structure is determined by using a Scanning Electron Microscope(SEM) or an Optical Microscope and an image analysis software. Amagnification of 200 to 10,000 times is chosen such that the fibrouselements are suitably enlarged for measurement. When using the SEM, thesamples are sputtered with gold or a palladium compound to avoidelectric charging and vibrations of the fibrous element in the electronbeam. A manual procedure for determining the fibrous element diametersis used from the image (on monitor screen) taken with the SEM or theoptical microscope. Using a mouse and a cursor tool, the edge of arandomly selected fibrous element is sought and then measured across itswidth (i.e., perpendicular to fibrous element direction at that point)to the other edge of the fibrous element. A scaled and calibrated imageanalysis tool provides the scaling to get actual reading in μm. Forfibrous elements within a fibrous structure, several fibrous elementsare randomly selected across the sample of the fibrous structure usingthe SEM or the optical microscope. At least two portions of the fibrousstructure are cut and tested in this manner. Altogether at least 100such measurements are made and then all data are recorded forstatistical analysis. The recorded data are used to calculate average(mean) of the fibrous element diameters, standard deviation of thefibrous element diameters, and median of the fibrous element diameters.

Another useful statistic is the calculation of the amount of thepopulation of fibrous elements that is below a certain upper limit. Todetermine this statistic, the software is programmed to count how manyresults of the fibrous element diameters are below an upper limit andthat count (divided by total number of data and multiplied by 100%) isreported in percent as percent below the upper limit, such as percentbelow 1 micrometer diameter or %-submicron, for example. We denote themeasured diameter (in μm) of an individual circular fibrous element asdi.

In the case that the fibrous elements have non-circular cross-sections,the measurement of the fibrous element diameter is determined as and setequal to the hydraulic diameter which is four times the cross-sectionalarea of the fibrous element divided by the perimeter of thecross-section of the fibrous element (outer perimeter in case of hollowfibrous elements). The number-average diameter, alternatively averagediameter is calculated as:

$d_{num} = \frac{\sum\limits_{i = 1}^{n}\; d_{i}}{n}$Air Permeability Test Method

The Air Permeability Parameter is determined using the Air PermeabilityTest Method, which is based on EDANA 140.1-99. In the Air PermeabilityTest Method, three specimens from three separate articles areinterrogated with an air permeability device that measures the air flowthrough a specimen required to maintain a preset pressure differenceacross that same specimen. All measurements are done at 50±5% relativehumidity and 23±2° C., and all samples are equilibrated in this sameenvironment for at least twelve hours prior to testing.

Three specimens are prepared, each from one of three representativearticles. Each specimen is a circular disc 5 cm in diameter centered onthe intersection of the longitudinal and lateral centerlines of thearticle.

Air permeability is determined using the Textest FX3300 LabAir III(Textest AG, Schwerzenbach, Switzerland) or equivalent instrumentoutfitted with a circular 5 cm² test head (diameter=2.52 cm). In thisconfiguration, the instrument is capable of measuring air flow rates perunit area of between 4 liters per square meter per second (L/m²/s) and7500 L/m²/s at a pressure differential of 125 Pa. The instrument ispowered on and calibrated with a calibration plate according to themanufacturer's instructions. The differential pressure for allmeasurements is set to 125 Pa. Each specimen is then measured by placingit (centered) within the test head such that the air pathway iscompletely covered by the specimen and recording the resultingsteady-state air flow rate to three significant figures. (If fewer thanthree significant figures are displayed on the instrument readout, theair flow rate is recorded to the number of significant figuresdisplayed.) The resulting air flow rate for each specimen is divided bythe area of the test head (5 cm²) to obtain a flow rate per unit area inL/m²/s. If the specimen has insufficient permeability to allow for ameasurable air flow rate at a differential pressure of 125 Pa, the airflow rate per unit area is defined to be 4 L/m²/s. If the specimen haspermeability so high such that 125 Pa of differential pressure cannot bemaintained even at the high end of the instrument's volumetric flowrange, the air flow rate per unit area is defined to be 7500 L/m²/s. Thearithmetic mean of the air flow rates per unit area from each of thethree specimens is defined as the Air Permeability Parameter and isreported to 3 significant figures.

Free Melt Flow Test Method

The Free Melt Flow Parameter is determined using the Free Melt Flow TestMethod. In this method, a specimen taken from an article(s) is held atan elevated temperature for an extended period of time in closeproximity to an absorbent medium, and the propensity of material fromthe article to melt, flow, and be absorbed by the absorbent medium isquantified.

The ambient conditions of the laboratory are 23±2° C. and 40±10%relative humidity. Seven sheets of 150-mm diameter Grade 4 filter paper(such as Whatman 1004-150, GE Healthcare Bio-Sciences, or equivalent)are stacked and the mass is recorded to within ±0.01 g. This is theinitial filter paper mass. The stack of filter paper is then placed ontoa stainless steel grating (the lower grating) that extends beyond the150-mm outer diameter of the filter paper. The grating is composed ofsolid parallel rods 3.4 mm in diameter and spaced 12.5 mm on center in aplanar configuration. The grating comprises a frame or end rails to holdthe rods in place, with the frame or rails beyond the outer edges of thefilter paper. An identical grating (the upper grating) is then placed ontop of the stack of filter paper such that the filter paper is captivebetween the two gratings (the grating assembly). The upper and lowergratings are oriented such that the constituent rods of the two gratingsare parallel to each other and “registered” such that the rods of thetwo gratings are directly above one another in a vertical direction.

The mass of the specimen to be analyzed is 2.0±0.1 g, measured to within±0.01 g. A 50 mm×50 mm square of material is cut from the center of thearticle. If this 50 mm×50 mm square weighs 2.0±0.1 g, it is the specimenused for the analysis. If this 50 mm×50 mm square weighs more than 2.1g, it is resampled in its center with a smaller square of mass 2.0±0.1g, and this resulting smaller square is the specimen used for theanalysis. If this 50 mm×50 mm square weighs less than 1.9 g, additional50 mm×50 mm squares are cut from the centers of like articles andstacked until the total mass is 2.0±0.1 g, and this stack is thespecimen used for the analysis. (In this case, the final 50 mm×50 mmsquare used may be subsampled in its center in order to achieve thespecified target mass of the specimen.) The specimen is then placed onthe top grating such that it is centered over the stack of filter paper.This entire assembly is then placed (such that in an oven held at 80° C.for a duration of 24.0 hours. The racks are supported such that there isfree space above the specimen and below the lower grating where the 150mm-diameter filter paper is positioned (that is, the lower grating isnot resting on the oven floor).

At the end of the 24-hour period, the grating assembly is removed fromthe oven, and the filter paper is removed from the between the lower andupper gratings and allowed to re-equilibrate for 1 hour to ambient labconditions. The mass of the filter paper along with any absorbedmaterial from the article, defined as the final filter paper mass, isthen determined to within ±0.01 g. The Free Melt Flow Parameter iscalculated according to the equation below:

${{Free}\mspace{14mu}{Melt}\mspace{14mu}{Flow}\mspace{14mu}{Parameter}} = \frac{\begin{matrix}{100\% \times \left( {{{Final}\mspace{14mu}{Filter}\mspace{14mu}{Paper}\mspace{14mu}{Mass}} -} \right.} \\\left. {{Initial}\mspace{14mu}{Filter}\mspace{14mu}{Paper}\mspace{14mu}{Mass}} \right)\end{matrix}}{{Specimen}\mspace{14mu}{Mass}}$

The Free Melt Flow Parameter is reported as a percent rounded to thenearest integer percent value.

Lamellar Structure Test Method

The Lamellar Structure Test Method makes use of small-angle x-rayscattering (SAXS) to determine if a lamellar structure is present in anarticle either in a conditioned, dry state or upon wetting after havingbeen previously in a conditioned, dry state. Fibrous material articlesare conditioned at a temperature of 23° C.±2.0° C. and a relativehumidity of 40%±10% for a minimum of 12 hours prior to the test.Articles conditioned as described herein are considered to be in aconditioned, dry state for the purposes of this invention. Allinstruments are calibrated according to manufacturer's specifications.

Dry Sample Preparation

To prepare a sample to be analyzed directly in the conditioned, drystate, a specimen of about 1.0 cm diameter disc is isolated from thecenter of an article and is loaded into a conventional SAXS solid sampleholder with aperture diameter between 4 and 5 mm. Multiple specimendiscs may be extracted from multiple articles and stacked, if necessary,to ensure sufficient scattering cross-section. The loaded sample holderis immediately placed in the appropriate instrument for data collection.

Wet Sample Preparation

Three samples are analyzed upon wetting from the dry, conditioned state.Specimens are extracted from dry, conditioned articles and hydrated withwater in order to achieve three separate preparations each possessing adifferent specimen-to-water mass ratio. The three differentspecimen-to-water mass ratios to be prepared are 1:5, 1:9, and 1:20. Foreach mass ratio, one or more specimens (as needed) 1 cm in diameter areextracted from the geometric centers of one or more articles in the dry,conditioned state are hydrated with 23° C.±2.0° C. filtered deionized(DI) water in order to achieve the intended specimen-to-water massratio. Each of the three specimen/water mixtures (each corresponding toa different mass ratio) is stirred under low shear gently by hand atroom temperature using a spatula until visibly homogenous. Eachspecimen/water mixture is then immediately loaded into a separate quartzcapillary tube with outer diameter 2.0 mm in diameter and 0.01 mm wallthickness. The capillary tubes are immediately sealed with a sealantsuch as an epoxy resin to prevent the evaporation of water from thepreparations. The sealant is permitted to dry for at least 2 hours anduntil dry at a temperature of 23° C.±2.0° C. prior to sample analysis.Each prepared wet sample is introduced into an appropriate SAXSinstrument and data are collected.

Testing and Analysis

Samples are tested using SAXS in 2-dimension (2D) transmission mode overan angular range in of 0.3° to 3.0° 2θ, to observe the presence andspacing of any intensity bands in the x-ray scattering pattern. The testis conducted using a SAXS instrument (such as the NanoSTAR, Bruker AXSInc., Madison, Wis., U.S.A., or equivalent). Conditioned, dry samplesare analyzed under ambient pressure. Sealed liquid samples are analyzedin the instrument under vacuum. All samples are analyzed at atemperature of 23° C.±2.0° C. The x-ray tube of the instrument isoperated at sufficient power to ensure that any scattering bands presentare clearly detected. The beam diameter is 550±50 μm. One suitable setof operating conditions includes the following selections: NanoSTARinstrument; micro-focus Cu x-ray tube using the Kα line at 1.54 Å; 45 kVand 0.650 mA power; Vantec2K 2-Dimensional area detector; collectiontime of 1200 seconds; and distance between the sample and detector of112.050 cm. The raw 2-D SAXS scattering pattern is integratedazimuthally to determine intensity (I) as a function of the scatteringvector (q), which are expressed throughout this method units ofreciprocal angstroms (Å⁻¹). The values for q are calculated by the SAXSinstrument according to the following equation:

$q = {\frac{4\pi}{\lambda}\sin\mspace{14mu}\theta}$

where:

2θ is the scattering angle; and

λ is the wavelength used.

For each integrated SAXS analyzed, the value of q in Å⁻¹ correspondingto each intensity peak on the plot of I vs q is identified and recordedfrom smallest to largest. (One of skill in the art knows that a sharppeak in q near the origin corresponds to scatter off of the beam stopand is disregarded in this method.) The value of q corresponding to thefirst intensity peak (the lowest value of q) is referred to as q*.

For a sample corresponding to a specimen (taken from a fibrous materialarticle) analyzed directly in the dry, conditioned state, if anintensity peak is present at 2q*±0.002 Å⁻¹, then the fibrous material ofwhich the article is composed is determined to exhibit a lamellarstructure, and the characteristic d-spacing parameter is defined as2π/q*. If no intensity peak is present at 2q*±0.002 Å⁻¹, then thefibrous material of which the article is composed is determined to notexhibit a lamellar structure.

For a sample analyzed upon wetting from the dry, conditioned state, ifan intensity peak is present at 2q*±0.002 Å⁻¹, the sample is determinedto exhibit a lamellar structure, and the characteristic d-spacingparameter is defined as 2π/q*. If no intensity peak is present at2q*±0.002 Å⁻¹, the sample is determined to not exhibit a lamellarstructure. If a lamellar structure is determined to be present in atleast any one of the three specimen/water ratios prepared, then thematerial of which the articles are composed is determined to exhibit alamellar structure upon wetting. If no intensity peak is present at2q*±0.002 Å⁻¹, in any of the three specimen/water ratios prepared, thenthe material of which the articles are composed is determined to notexhibit a lamellar structure upon wetting.

Fibrous Element Composition Test Method

In order to prepare fibrous elements for fibrous element compositionmeasurement, the fibrous elements must be conditioned by removing anycoating compositions and/or materials present on the external surfacesof the fibrous elements that are removable. An example of a method fordoing so is washing the fibrous elements 3 times with a suitable solventthat will remove the external coating while leaving the fibrous elementsunaltered. The fibrous elements are then air dried at 23° C.±1.0° C.until the fibrous elements comprise less than 10% moisture. A chemicalanalysis of the conditioned fibrous elements is then completed todetermine the compositional make-up of the fibrous elements with respectto the filament-forming materials and the active agents and the level ofthe filament-forming materials and active agents present in the fibrouselements.

The compositional make-up of the fibrous elements with respect to thefilament-forming material and the active agents can also be determinedby completing a cross-section analysis using TOF-SIMs or SEM. Stillanother method for determining compositional make-up of the fibrouselements uses a fluorescent dye as a marker. In addition, as always, amanufacturer of fibrous elements should know the compositions of theirfibrous elements.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A consumable, single use solid articlecomprising: a. one or more active agents present in the consumable,single use solid article; and b. one or more auxiliary ingredients;wherein the consumable, single use solid article disappears duringautomatic clothes dryer use; wherein the consumable, single use solidarticle exhibits an article density of less than about 0.80 g/cm³ asmeasured according to the density test method; and wherein theconsumable, single use solid article exhibits a free melt flow of morethan about 20% as measured according to the free melt flow test method.2. The consumable, single use solid article according to claim 1 whereinthe consumable, single use solid article comprises greater than 90% byweight of the one or more active agents.
 3. The consumable, single usesolid article according to claim 1 wherein at least one of the one ormore active agents comprises a fabric conditioning active agent.
 4. Theconsumable, single use solid article according to claim 3 wherein thefabric conditioning active agent is selected from the group consistingof: fatty acids, fatty acid derivatives, sulfonic acid derivatives,quaternary ammonium compounds, tertiary amines and salts thereof,nonionic surfactants, fatty alcohols, and mixtures thereof.
 5. Theconsumable, single use solid article according to claim 4 wherein thefabric conditioning active agent comprises a fatty acid selected fromthe group consisting of: myristic acid, stearic acid, isostearic acid,cetearic acid, dodecanoic acid, linoleic acid, oleic acid, palmiticacid, lauric acid, and mixtures thereof.
 6. The consumable, single usesolid article according to claim 4 wherein the fabric conditioningactive agent comprises a quaternary ammonium compound selected from thegroup consisting of:di(tallowyloxyethyl)hydroxyethylmethylammoniummethylsulfate, dimethylbis(stearoyl oxyethyl)ammonium chloride, dimethylbis(tallowyloxyethyl)ammonium chloride, dimethylbis(tallowyloxyisopropyl)ammonium methylsulfate, and mixtures thereof.7. The consumable, single use solid article according to claim 4 whereinthe fabric conditioning active agent comprises a fatty alcohol selectedfrom the group consisting of: cetyl alcohol, stearyl alcohol, behenylalcohol, lauryl alcohol, myristic alcohol, isostearyl alcohol, arachidylalcohol, and mixtures thereof.
 8. The consumable, single use solidarticle according to claim 4 wherein the fabric conditioning activeagent comprises a fatty alcohol and a quaternary ammonium compound. 9.The consumable, single use solid article according to claim 8 whereinthe fatty alcohol and quaternary ammonium compound are present in thesolid article at a weight ratio of greater than 1:1.
 10. The consumable,single use solid article according to claim 4 wherein the fabricconditioning active agent comprises a fatty acid and a quaternaryammonium compound.
 11. The consumable, single use solid articleaccording to claim 10 wherein the fatty acid and quaternary ammoniumcompound are present in the solid article at a weight ratio of greaterthan 1:1.
 12. The consumable, single use solid article according toclaim 1 wherein at least one of the one or more active agents isselected from the group consisting of: fabric care active agents,dishwashing active agents, carpet care active agents, surface careactive agents, hair care active agents, air care active agents, oralcare active agents, dryer added active agents, and mixtures thereof. 13.The consumable, single use solid article according to claim 12 whereinat least one of the one or more active agents is selected from the groupconsisting of: perfumes, builders, chelants, antioxidants, brighteners,sun fade inhibiting agents, UV absorbing agents, insect repellants,scents, bleaching agents, enzymes, antimicrobials, antibacterials,antifungals, perfume delivery systems, perfume microcapsules, dyetransfer inhibiting agents, hueing dyes, soil release agents, colorants,preservatives, opacifiers, stabilizers, anti-shrinkage agents,anti-wrinkle agents, fabric crisping agents, reductive agents, spottingagents, germicides, fungicides, anti-corrosion agents, and mixturesthereof.
 14. The consumable, single use solid article according to claim1 wherein at least one of the one or more auxiliary ingredientscomprises a structurant.
 15. The consumable, single use solid articleaccording to claim 1 wherein at least one of the one or more auxiliaryingredients is dispersed throughout the one or more active agents. 16.The consumable, single use solid article according to claim 1 whereinthe consumable, single use solid article comprises one or more fibrouselements.
 17. The consumable, single use solid article according toclaim 1 wherein the consumable, single use solid article exhibits one ormore of the following characteristics: a. a width from about 1 cm toabout 15 cm; b. a length from about 1 cm to about 23 cm; c. a heightfrom about 0.01 mm to about 50 mm; d. a mass from about 0.10 g to about10 g; e. a volume from about 0.25 cm³ to about 60.00 cm³; and f. adensity from about 0.05 g/cm³ to about 0.80 g/cm³.
 18. The consumable,single use solid article according to claim 1 wherein the consumable,single use solid article exhibits a lamellar structure response asmeasured according to the lamellar structure test method.
 19. Theconsumable, single use solid article according to claim 1 wherein theconsumable, single use solid article exhibits a lamellar structureresponse in a wet state but does not exhibit a lamellar structureresponse in a dry state as measured according to the lamellar structuretest method.